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Keston Combi 35kw User's Manual

1. 20 BE Oo continued INSTALLATION INSTALLATION 8 FLUESYSTEM IMPORTANT When installing a replacement boiler a new flue system must be used DO NOT re use the existing boiler flue installation DESIGN Individual air supply and flue outlet pipes are used as standard The material approved for this application is which MUST be used is Marley muPVC Solvent Weld System 50mm and Polypipe System 2000 muPVC solvent weld 50mm to BS5255 and or BSEN1566 11 and BSEN1329 are the only systems approved for this application The following pipe and fittings are approved Polypipe System 2000 muPVC solvent Weld System 50mm MU 301 4m length muPVC wastepipe 5 225 Mareycoee o Consideration MUST be given to expansion and contraction of the flue Refer to Assembly Practice Frame in this installation and Servicing Instructions for further guidance continued 14 Keston Combi Installation and Servicing INSTALLATION 9 FLUESYSTEM CONT D TERMINATION OF THE FLUE AND AIR The flue and air pipes may terminate independently through any external walls within the same dwelling except on opposing walls within the maximum lengths shown in graph below TERMINAL POSITIONS The air pipe must have an elbow and 150mm length of pipe directed downwards with a termination grill fitted The air pipe can be situated at the side or beneath the flue pipe to a
2. Remove the old seal from the casing and thoroughly clean the casing surfaces Fit the new seal ensuring the bottom joint provides an air tight seal 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frame 36 Note Ensure that the boiler front panel is correctly sealed compressing the seal to make an airtight joint Recharge Point Keston Combi Installation and Servicing FAULT FINDING 75 FAULT FINDING CHART MAIN MENU Note Boiler status display information is shown in shaded boxes below Up to six messages will be displayed in rotation Overheat lockout 1 Fill system to 1 0 bar 2 Bleed radiators Go to Frame 76 3 Check radiator valves open 4 Reset boiler 5 Contact installer Flow Temperature Overheat Lockout Ignition lockout Eire Oaea 1 Check other gas appliances work Go to Frame 77 2 Reset boiler 3 Contact Installer Ignition Lockout 5 Resets with 15 minutes Contact installer Turn power off and on Go to Frame 78 Fault 8 Contact installer Fase Fiame Lockout 1 Fill system to 1 0 bar H 2 Bleed radiators H3 Contact installer Da a an Flame loss 1 Check other gas appliances H2 contact installer Go to Frame 80 Flame Loss Go to Frame 81 Fan Fault Fan fault Contact installer Go to Frame 82 Contact installer Return Thermistor Fault Return thermistor fault Go to Frame 83 Outside sensor fault i Low mains voltage Low mains voltage Contact electricity provider Contact E
3. 2 Connect the CH rtn valve black handle and copper tail 3 If connecting the boiler to heating loads in excess of 60 000 Btu h connecting flow and return heating systems pipework must be sized in 28mm diameter at the point of pipe connection to the boiler tails use 22mm x 28mm pipe adaptors as appropriate WATER CONNECTIONS DHW 1 Fit the DHW inlet service valve blue handle and copper tail to the threaded boss connection ensuring the seal provided is correctly located 2 Fit the DHW outlet pipe tail to DHW outlet connection ensuring the seal provided is correctly located 3 Fit the filling loop provided between the DHW inlet valve and the CH return valve GAS CONNECTION IMPORTANT The gas service cock is sealed with a non metallic blue fibre washer which must not be overheated when making capillary connections Refer to Frame 1 for details of the position of the gas connection For additional gas supply info refer to Gas Supply on page 8 SAFETY VALVE DRAIN The safety valve connection located at the bottom right hand side of the boiler comprises a 15mm diameter stub pipe The Installer to provide a compression joint on the end of the stub pipe This assists with pipe removal when servicing The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring CH Flow Handle I Note tha
4. 3 Turn and hold the mode knob in the reset position for more than 5 secs and then turn it to the Winter or Summer position The boiler will display Installer mode If no faults have occurred the boiler will display No faults If any faults have occurred a list of faults up to a maximum of 10 including the type of fault and how long ago it occurred will be shown in the following format LIST OF FAULTS Fault 2 No water flow lockout 78 days ago Fault 3 Overheat lockout 384 days ago The boiler will then display the current values of flow temperature return temperature domestic hot water temperature DHW flow rate and diverter valve position in the following format 3G9713a Note MESSAGE1 If you would like to hold one of the values on the display to watch DCURRENTVALUES its behaviour then turn the reset knob to the reset position while it is CURRENT VALUES displayed and hold it there Finally the display will operate in one of two modes If there is a Flow temp 80 C i U fault then more extensive corrective actions will be shown than are Return temp 60 C usually displayed for the end user If there is not a fault then the information displayed for current operating states will also be more DHW temp 64 C extensive than is usually displayed for the end user pre purge i ignition and post purge for example DHW flow rate 8 l min Installer mode automatically ends after 10 mins or by moving the mo
5. Injector 38 Keston Combi Installation and Servicing SERVICING 41 BURNER REMOVAL AND CLEANING Ensure the sump is fully drained Undo the two screws and remove the sump cover retaining the lower flue manifold Lift the manifold to clear the bottom sealing gasket and remove manifold Remove the 2 burner front fixing screws and loosen the 2 rear extended nuts by at least ten turns Lift off the burner from the combustion chamber To facilitate the removal angle the burner as shown IMPORTANT The burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic Brush off any deposits that may be on the ceramic with a SOFT brush Inspect the sealing gasket around the burner for any signs of damage Replace as necessary 42 CLEANING THE CONDENSATE TRAP SIPHON Pull off the rubber pipe at the sump drain 4 Clean siphon with water Disconnect the condensate drain pipe 5 Re assemble in reverse order Turn the siphon clockwise to disengage and lift to B When re assembling ensure the trap is full of water remove Note Keep siphon upright when removing Si A 7 CT om Toe lit AW V IA R re 3G9690 Keston Combi Installation and Servicing 39 SERVICING SERVICING SERVICING 43 CLEANING THE HEAT EXCHANGER Note Ensure the condensate trap siphon is
6. O D as 1 4 g 18 5 14 6 Acceptable Operating Area r 2 2 4 6 8 10 12 14 16 18 20 22 24 26 28 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Flue Pipe Length m Flue Pipe Length m ii SLOPE D Horizontal flue outlet pipework MUST slope at least 1 5 degrees 26mm per metre run downwards towards the boiler Pipework can be vertical Only swept elbows can be used iall Air inlet pipework can be truly horizontal or vertical or sloping in a downward direction towards the boiler but in each case rain etc must be prevented from entering the pipe There must be no troughs in any of the pipework whether it be air inlet or flue outlet Keston Combi Installation and Servicing 15 INSTALLATION 10 FLUE INSTALLATION EXAMPLE KESTON COMBI 30 Keston Combi 30 Flue amp Air Pipe Length 1 5 back to boiler Bracket at each 1 metre 6m Air Pipe Length m Acceptable Operating Area 10 12 14 16 18 20 22 24 26 28 30 1 5 back to boiler 4 6 8 NANANANNNNANNNNNNNNNNSN Flue Pipe Length m Calculations Air Flue Elbows 2 x 1m 2m Elbows 3 x 1m 3m Straights 6 2 0 15 8 15m Straights 4 6 1 5 1 12 5m Total 10 15m Total 15 5m Overall Flue Air 25 65m 11 FLUE INSTALLATION EXAMPLE KESTON COMBI 35 Keston Combi 35 Flue amp Air Pipe Length F a GS S A 15 Air fT ae Z 0 15m Am al 1 5 back to boiler 3 5m 1 5m 2m ue Sees Brack
7. Combi 30 amp 35 Installation and Servicing Instructions FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS COMBINATION BOILER CE PI No 86 CL 38 Combi 30 GC No 47 930 04 Combi 35 GC No 47 930 05 C These Instructions must be left either with the user or next to the site gas meter Keston Heating PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 44 0 1482 443005 Fax 44 0 1482 467133 email info keston co uk web www keston co uk COMPLIANT WITH BUILDING REGULATION PART L1 amp L2 SEDBUK A RATED Ob enchmark gt Keston Combi Installation and Servicing NOTES FOR THE INSTALLER FOR ANY TECHNICAL QUERIES PLEASE RING THE KESTON INSTALLER TECHNICAL HELPLINE 01482 443005 NOTE BOILER RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level A02 Oct 12 and A03 Feb 14 Page 11 Water Treatment Addition of Adey Professional Heating Solutions Page 31 Item 3 added to Electrical Installation Statement added ref to commissioning process of combustion Page 67 New Page Added Benchmark Commissiong amp Servicing Section Page 68 amp 69 New updated Commissioning Checklist amp Service Record Sheets Page 70 amp 71 New pag
8. Gas rate OR Burner operating pressure if applicable OR Gas inlet pressure Central heating flow temperature Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate m hr OR Burner operating pressure at maximum rate mbar OR Gas inlet pressure at maximum rate Cold water inlet temperature Hot water has been checked at all outlets Yes Temperature Water flow rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 ALL INSTALLATIONS At max rate CO ppm CO CO Record the following At min rate where possible CO ppm CO CO The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Cus
9. IF th pes I se Emerald Way Stone Staffordshire ST15 OSR e boiler is installed in an existing system any Tel 44 0 1785 811636 unsuitable additives MUST be removed by thorough l cleansing BS 7593 2006 details the steps necessary to Calmag Ltd clean a domestic heating system Unit 3 6 Crown Works Bradford Road Sandbeds Keighley In hard water areas treatment to prevent lime scale may West Yorkshire BD20 SLN be necessary however the use of artificially softened Tel 44 0 1535 210 320 water is NOT permitted Adey Professional Heating Solutions Under no circumstances should the boiler be fired Gloucester Road Cheltenham GL51 8NR before the system has been thoroughly flushed Tel 44 0 1242 546700 Keston Combi Installation and Servicing 11 INSTALLATION INSTALLATION 6 BOILER ASSEMBLY Exploded View 309 Thermistor No Flow 104 CH Return Valve 120 Flow Group Manifold 218 Gasket Burner re 105 CH Flow Valve 121 Plate Heat Exchanger 219 Sump Clean Out Cover 313 Ignition Lead 106 DHW Inlet amp Outlet 127 Flow Sensor Hall Effect 223 Flue Manifold 314 Control Box Lens 107 Filling Loop 128 Flow Turbine Cartridge 224 Flue Manifold Top 324 Controls Box Lid 108 Pump Head 131 Water Pressure Transducer 227 Clamp Retaining Flue Turret 325 Control Box Front 110 Air Vent Pump 135 Pressure Gauge 228 Hose Condensate Internal 326 Programmer Insert 111 Diverter Valve Head 136 Safety Valve Drain Pipe 229 Siphon Trap 332 Flue
10. Keston Combi Installation and Servicing 65 Code Of Practice For the installation commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations Installers are required to carry out work in accordance with the following THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The use of the word installer is not limited to installation itself and covers those carrying out installation commissioning and or servicing of heating and hot water products or the use of supporting products Such as water treatment or test equipment Customer includes householders landlords and tenants Heating and Hotwater Industry Council HHIC Standards of Work Be competent and qualified to undertake the work required Install commission service and use products in accordance with the manufacturer s instructions provided Ensure that where there is responsibility for design work the installation is correctly sized and fit for purpose Meet the requirements of the appropriate B
11. 36 48 Potentiometer spindle Keston Combi Installation and Servicing SERVICING 60 DRAINING THE BOILER CENTRAL HEATING CIRCUIT 1 Refer to Frame 45 2 Close all the CH water isolating valves on the boiler inlet wan V 3 To drain the primary heat exchanger circuit Open the drain valve and attach a length of hose to the CH drain point t IRL A lt N I ZZ T I 4 After replacing any component on the boiler remove the hose close the drain valve and open all system isolating valves re pressurise as appropriate by re connecting the filling loop refer to Frame 22 before proceeding to check operation of the boiler re 5 Disconnect filling loop Refer to Frame 22 3G9690 6 Check operation of the boiler Refer to Frames 36 IL Lee DOMESTIC HOT WATER CIRCUIT mG ry 1 Refer to Frame 45 2 Close all the DHW water isolating valves on the boiler inlet 3 To drain the domestic hot water circuit As there is no direct drain for the domestic hot water circuit depending on the location of the boiler opening the lowest hot water tap may drain this circuit However it must be noted that some residual water will be experienced during replacement of components tp AW Q E 1 la rO 4 After replacing any component on the boiler close tap close the drain valve and open all system isolating valves re 3G9690 pressurise as appropriate by re connecting the fi
12. 55 Remove the 2 allen screws securing the plate heat exchanger to the brass housings Manoeuvre the plate heat exchanger out of the top LH or centre of the controls area 67 PUMP HEAD REPLACEMENT Refer to Frame 45 2 Drain the boiler Refer to Frame 60 3 Disconnect the electrical plug from the pump Remove the 4 Allen screws retaining the pump head Remove the pump head Fit the new pump head Reassemble in reverse order Refill the boiler Refer to Frame 22 Check operation of the boiler Refer to Frame 36 66 DHW PLATE HEAT EXCHANGER REPLACEMENT Fit the new plate heat exchanger using the new o rings supplied Note The mounting pins are offset so the correct position can be defined from the location of the holes on the brass mounting Reassemble in reverse order 9 Refill the boiler Refer to Frame 22 10 Check operation of the boiler Refer to Frame 36 4A GRUNDFOS Type UPO1S 60 CESAO3 P N 96878772 230V PC 0941F UG Keston Combi Installation and Servicing SERVICING 68 CH WATER PRESSURE SENSOR REPLACEMENT 1 Refer to Frame 45 2 Drain the boiler Refer to Frame 60 Remove condensate trap siphon Refer to Frame 56 4 Using a suitable tool pull out the retaining clip 5 Pull the pressure sensor upwards to remove 6 Unplug the electrical connection and transfer to the new pressure sensor Push the new pressure sensor onto the rear
13. BS 7671 Wiring Regulations and any local regulations Frost Protection If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system This is usually done at the programmer in which case the programmer selector switches are set to OFF and all the other controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system Note f the boiler is installed in a garage it may be necessary to fit a pipe thermostat preferably on the return pipework Earths are not shown for clarity but must never be omitted OpenTherm Programmable Room Temperature Control Note These terminals MUST ONLY be connected to an OpenTherm Controller such as the Keston Chronothern Room Controller c 17 4 21 00 0 _ Connecting any other device control wiring may destroy the primary PCB 1 2 3 Isolate the mains supply to the boiler Remove the front panel Refer to Frame 39 Swing the control box down into the servicing position Refer to Frame 45 Remove the control box cover Refer to Frame 57 no s 3 and 4 Unclip the 3 way in line connector containing 2 purple wires and 2 red wires Connect this 3 way connector to the 3 way connector containing 2 purple wires wired from the 4 way terminal block Connect the two wires from the OpenTherm Programmable Room
14. See note regarding thermostatic radiator valves on page 8 Note Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass BALANCING 1 Set the programmer to ON Close the manual or thermostatic valves on all radiators leaving the twin lockshield valves on the radiators referred to above in the OPEN position Turn up the room thermostat and adjust the lockshield valve to give an uninterrupted flow through Hard Water Areas the radiator Where the water hardness exceeds 200mgl litre it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply within the requirements of the f f local water company Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining IMPORTANT radiators to give around 20 C temperature drop at Provision MUST be made to accommodate the expansion of DHW each radiator contained within the appliance if a non return valve is fitted to the DHW inlet or a water meter with a non return valve is installed Adjust the room thermostat and programmer to Cold water rising main and pipework in exposed areas need to NORMAL settings be suitably lagged to prevent freezing These valves should now be left as set 5 WATER TREATMENT DOMESTIC HOT WATER CENTRAL HEATING In hard water areas where mains water can exceed 200ppm The Keston Combi range boiler has an ALUMINIUM alloy
15. The ECGA should be of the correct type as specified by BS 7967 Prior to its use the ECGA should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer s instructions KEY CO carbon monoxide CO gt carbon dioxide O2 oxygen Combustion Ratio The CO reading measured in ppm divided by the COz reading first converted to ppm ppm parts per million GS I amp U R Gas Safety Installation and Use Regulations Setting to Minimum Rate Turn the CH temperature control knob into the 10 O clock position Create a CH demand by ensuring that the system controls are requesting heat and the boiler Mode Knob is in the Winter Position Within an overall time of 3 seconds turn the CH temperature control knob fully clockwise back to 10 O clock and then fully clockwise again The following messages will be shown in rotation on the display Service Mode Minimum Output Move CH Knob to End and the boiler output will be reduced to minimum 5 The boiler will remain at minimum rate for 5 minutes before reverting to normal operation Keston Combi Installation and Servicing Carry Out Flue Integrity Check Using Analyser Insert analyser probe into air inlet test point where available and allow readings to stabilise Note Where no air inlet
16. and Servicing INSTALLATION 16 FITTING THE WALL MOUNTING PLATE 17 MOUNTING THE BOILER Ensure the plastic plugs are removed from both the CH Screw the wall mounting plate to the wall using 2 wall plugs and DHW connections before mounting the boiler previously fitted with the 2 screws provided Lift the boiler onto the wall mounting plate refer to the Introduction section for safe handling advice locating it over the two tabs Choose one of the 2 sets of slots in left and right bank Ensuring that at least one of the screws is fitted into a top slot Example of fixing Keston Combi Installation and Servicing 19 INSTALLATION li J 0 ll J L 20 INSTALLATION 18 ASSEMBLY PRACTICE Remove all plastic debris and burrs when installing air intake piping Plastic fillings caused by cutting muPVC pipe must not be allowed to be drawn into the combustion air blower Prevent dust entering the air intake when cutting on building sites Blower failure which is determined to be caused by plastic filings or other debris will not be covered by guarantee INSTALLING FLUE AND AIR PIPES Important When installing the boiler on an existing system a new flue and air intake system MUST also be installed You MUST NOT re use existing flue or air pipework components Remove the flue adaptor and air spigot from the flue pack supplied with the boiler Remove boiler front panel Frame 39 Remo
17. any operational condition as shown below Notes Boiler frost protection boiler fires if temperature is below 5 C The temperatures shown below are for illustration purposes only The measured temperatures will be shown on the boiler DISPLAY FUNCTIONS IN NORMAL OPERATION Mode knob in standby position and no Standby mode For hot water turn mode For central heating turn heat demand knob clockwise mode knob clockwise twice Mode knob in summer position and no Summer mode For central heating turn heat demand mode knob clockwise Mode knob in winter position and no Winter mode Timer or room stat off heat demand Domestic hot water operation Temperature 64 C High efficiency e C L C Note High efficiency will not be shown for central heating operation if the central heating flow temperature knob is set to greater than 73 C cc FUNCTIONS SETTINGS CHANGED Pre heat knob moved to off So Pre heat off a DHW temperature knob moved 64 C DHW temp Hot water May not be achieved for temperature 64 C high flow rates in winter CH temperature knob moved 80 C CH temp Maximum radiator temperature 80 C L TL i Keston Combi Installation and Servicing 33 INSTALLATION INSTALLATION INSTALLATION 34 INITIAL LIGHTING CONT D INSTALLER MODE Installer Mode is entered as follows 1 Turn the DHW temperature control knob full anti clockwise 2 Turn the CH flow temperature control knob full anti clockwise
18. leaks Refer to Frame 22 for filling detail Check the operation of the safety valve by raising the water pressure until the valve lifts This should occur within 0 3bar of the preset lift pressure Release water from the system until the minimum system design pressure is reached 1 0 bar if the system is to be pre pressurised continued Keston Combi Installation and Servicing GENERAL 4 SYSTEM BALANCING 3 SYSTEM REQUIREMENTS cont d DOMESTIC HOT WATER 1 The domestic hot water service must be in accordance with BS 5546 and BS 6700 Refer to Table 1 for minimum and maximum working pressures In areas of low mains water pressures the domestic hot water regulator may be removed from the DHW flow turbine cartridge Refer to Frame 70 The boiler will require the flow rate to be set to obtain a temperature rise of 35 C at the tap furthest from the boiler The boiler is suitable for connection to most types of washing machine and dishwasher appliances When connecting to suitable showers ensure that a The cold inlet to the boiler is fitted with an approved anti vacuum or syphon non return valve b Hot and cold water supplies to the shower are of equal pressure The boiler does not normally need a bypass but at least some radiators on the heating circuit of load of at least 10 of the minimum boiler output must be provided with twin lockshield valves so that this minimum heating load is always available
19. minimum dimension of 140mm see diagram below It must not be sited above the flue pipe The flue and air pipes must extend by at least 40mm from the wall surface Condensing boiler emit a visible plume of water vapour from the i flue terminal this is normal It is the responsibility of the installer icing to judiciously select a terminal location that does not cause a Air Pipe nuisance Terminal If either the flue or air terminal is below a height of 2m from ground level a terminal guard must be fitted MAXIMUM LENGTHS Due to the resistance presented by extended flue length a slight reduction in maximum boiler output will occur where combined flue and air lengths in excess of 18 0m and 16 0m 50mm muPVC are used In such cases the boiler output will be reduced by 0 6 and 0 8 per additional metre The maximum lengths of both air inlet pipe and flue outlet pipe when no bends are used are as detailed in graphs below However each bend used has an equivalent length that must be deducted from the maximum straight length stated in graphs below Knuckle bends must not be fitted A 92 5 swept elbow is equivalent to 1 0m straight length A 45 bend is equivalent to 0 5m straight length It is possible to have variable flue and air lengths as described within the shaded area of graphs below Keston Combi 35 Flue amp Air Pipe Length Keston Combi 30 Flue amp Air Pipe Length 30 26 i lI 30 22 26 E 18 E 22
20. pack Pull off rubber terminal block cover Connect wires to terminal block as shown below Re assemble in reverse order continued 25 INSTALLATION INSTALLATION 26 INSTALLATION 25 INTERNAL WIRING CONT D Keston offer 2 kits as follows see individual kits for installation instructions Electronic Timer 7 day kit 7 day electronic CH timer fits into the control box of the boiler This can be fitted in conjunction with a room thermostat Features English language installation help messages DIAGRAM A N 1 ROOM THERMOSTAT WITH INTERNAL BOILER TIMER OR Internal Timer or 2 PROGRAMMABLE ROOM THERMOSTAT i asss 1 Remove link wire between room stat timer terminals 2 Connect room stat across terminals as shown in diagram A 3 If room stat has a neutral connection connect this to terminal N load in the fused spur Optional Frost Stat FROST OL STAT O OPTIONAL ROOM THERMOSTAT TIMER DIAGRAM B External 1 Remove link wire between room stat timer terminals 2 Connect room stat and programmer in series as shown in diagram B 3 If room stat has a neutral connection connect this to terminal N load in the fused spur FROST THERMOSTAT Optional Frost Stat If parts of the system are vulnerable to freezing or the programmer is likely to be left off during cold weather a frost stat should be fitted in conjunction with a pipe thermostat SIEROT 1 Positio
21. pump housing and fit retaining clip Reassemble in reverse order Refill the boiler Refer to Frame 22 10 Check Operation of the boiler Refer to Frame 36 69 DHW FILTER CLEANING REPLACEMENT Refer to Frame 45 Isolate the mains cold water supply to the boiler Drain the boiler DHW circuit Refer to Frame 60 Remove the DHW flow turbine cartridge Refer to Frame 64 Unscrew the flow regulator housing Remove the filter Clean or replace filter as necessary Reassemble in reverse order Refill the boiler Refer to Frame 22 10 Check Operation of the boiler Refer to Frame 36 Keston Combi Installation and Servicing 53 SERVICING SERVICING SERVICING 70 DHW FLOW REGULATOR CLEANING REPLACEMENT 1 Refer to Frame 45 Isolate the mains cold water supply to the boiler Drain the boiler DHW circuit Refer to Frame 60 Remove the DHW flow turbine cartridge Refer to Frame 69 5 Unscrew the flow regulator housing Inspect the flow regulator for any blockage and remove if necessary 7 Reassemble in reverse order 8 Refill the boiler Refer to Frame 22 9 Check Operation of the boiler Refer to Frame 36 71 NO FLOW THERMISTOR REPLACEMENT Refer to Frame 45 Drain down the boiler Refer to Frame 60 Unplug the electrical lead Unscrew the thermistor to facilitate removal a 13mm socket spanner should be used Fit the new thermistor using
22. remove venturi assembly noting the orientation of the venturi in relation to the fan body Transfer the venturi assembly to the new fan replacing the o ring if evidence of damage or deterioration is visible Fit the new fan venturi assembly ensuring the retaining tabs are correctly positioned and the fan outlet sealing gasket is correctly positioned and free from damage Refit the extended nut Reassemble the boiler in reverse order taking care not to overtighten the screw on the fan mounting bracket Check the operation of the boiler Refer to Frame 36 Keston Combi Installation and Servicing 41 SERVICING SERVICING SERVICING 47 BURNER INJECTOR REPLACEMENT Refer to Frame 45 Disconnect the electrical leads from the fan 3 Undo the gas pipe union connection to the injector housing Loosen the screw retaining the fan mounting bracket Lift and remove the fan and venturi assembly Remove the 2 injector housing screws Withdraw the injector housing Fit the new injector housing complete with injector Reassemble in reverse order ensuring that the new gas seal supplied is located correctly in the injector housing 10 Check operation of the boiler Refer to Frame 36 48 BURNER REPLACEMENT See Frame 39 Refer to Frame 45 Disconnect 2 flag terminals from the flue thermostat Undo the two screws and remove the sump cover Lift the manifold to clear the b
23. temperature in a space served by radiators not fitted with such a valve When thermostatic radiator valves are used the space heating temperature control over a living dining area or hallway having a heating requirement of at least 10 of the minimum boiler heat output should be achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves However if the system employs thermostatic radiator valves on all radiators or two port valves then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position ELECTRICAL SUPPLY WARNING This appliance must be earthed Wiring external to the appliance MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any local regulations which apply For IE reference should be made to the current ETCI rules for electrical installations The mains supply to the boiler and system wiring centre shall be through one common fused double pole isolator and for new heating systems and where practical replacement boiler installations the isolator shall be situated adjacent to the appliance CONDENSATE DRAIN Refer to Frames 20 amp 21 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and fittings in the condensate drainage system MUST be made of plastic no other materials may be used IMPORT
24. that if the cord anchorage should slip the current carrying conductors become taut before the earthing conductor Swing the control box back up into the operating position and re fit the front panel ensuring a good seal is made 27 FITTING THE WEATHER COMPENSATION KIT SUPPLIED AS STANDARD This kit provides the facility to apply outside air temperature control to the boiler Kit Contents water flow temperature which provides energy savings The outside sensor provided measures outside air temperature and sends a signal to the boiler which adjusts the A Outside Air Sensor maximum boiler flow temperature in response If outside air temperature is greater than the system design temperature the boiler flow temperature is reduced providing running cost savings The boiler will operate in the condensing mode more frequently increasing savings Once the sensor is fitted it is automatically detected The sensor operation may be configured by adjustment of the boiler operating parameters if necessary FITTING THE KIT 3610011 Note A timer should be fitted to the system so that CH will be switched off when appropriate Fitting the sensor The air sensor should be located on an external wall of the building to be heated Fix the sensor to a north north east facing wall to avoid direct radiation from the sun The air sensor should be located to avoid any heating effect from the boiler flue To fix the air sensor to the wall unscrew the se
25. working Gas Pressure Test Point SERVICE REQUIRED Function When the boiler has been installed for more than 1 year the following message will appear on the screen 12 Month Service Interval Request To cancel this message move the CH Temperature Control Knob away from the maximum position Then move the knob to the maximum position away from the maximum position and back into the maximum position again within 3s Service Mode will be shown on the screen this will disappear after 5 mins AIR VENTING Function The Air Venting function should not be required for this boiler e The Air Venting function operates for 5 mins as follows e Pump On for 50s Pump Off for 10s repeats 5 times e Diverter valve in hot water position for 30s then CH position for 30s repeats 5 times The function ends automatically To activate the Air Venting function proceed as follows Turn the DHW temperature control knob fully anti clockwise Turn the CH flow temperature control knob fully anti clockwise Turn and hold the Mode Knob in the Reset position for more than 5s and then turn it to the Winter or Summer position The boiler will display Installer Mode If no faults have occurred the boiler will display No Faults If any faults have occurred a list of faults up to a maximum of 10 including the type of fault and how long ago it occurred will be shown The boiler will then display the current values of
26. 5mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued Keston Combi Installation and Servicing INSTALLATION 21 CONDENSATE DRAIN CONT D Figure 3 Connection of a Condensate Pump Typical Method see manufacturers detailed instructions Visible air break Boiler with 75mm Pi sealed condensate trap Min 19mm Internal pipe Condensate pump Install in accordance with manufacturers instructions Figure 5 Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe only combined foul rainwater drain Boiler with 75mm sealed condensate trap Figure 4 Connection of condensate Drainage Pipe to External Soil amp Vent Stack Boiler Water weather with 75mm proof insulation sealed condensate trap Min 30mm Internal pipe Min 19mm Internal er Soil amp vent stack Minimum connection height up to 3 Boilers without 75mm sealed storeys condensate trap must be fitted with a 75mm trap and visible air break Figure 6 Connection of Condensate Drainage Pipe Upstream of a Sink Basin Bath or Shower Waste Trap to External Drain Gulley or Ranwater Hopper Boiler with 75mm sealed condensate Visible air break trap at plug hole Min 19mm Internal pipe weather proof insulation combined foul rain water drain Min 19mm Water weather proof Min 30mm Internal pipe External air break Air gap Termi
27. ANT Any external runs must be in accordance with BS 6798 The drain outlet on the boiler is sized for standard 21 5mm 3 4 overflow pipe It is a universal fitting to allow use of different brands of pipework Keston Combi Installation and Servicing GENERAL 1 BOILER DIMENSIONS SERVICES amp CLEARANCES all dimensions in mm The boiler connections are made on the boiler connection tails Refer to Frame 22 The following minimum clearances must be maintained for operation and servicing Additional space will be required for installation depending upon site conditions CLEARANCES BOILER DIMENSIONS 2 5 E a case Minimum Top Te aye See h L i UPIP Y s IE fo H Centre line of boiler 43 65 I CH Flow x DHW Outlot DHW Inlet Gas Inlet Condensate Drain CH Return Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required with the cupboard door open to allow for servicing Bottom clearance Bottom clearance after installation can be reduced to 5mm This must be obtained with an easily removable panel to enable the consumer to view the system pressure gauge and to provide the 100mm clearance required for
28. Heat exchanger Reassemble in reverse order ensuring the heat exchanger LH retaining bracket is correctly positioned Replace any new oO rings supplied with new heat exchanger and replacing gaskets or seals if any sign of damage is evident When replacing the spring clips located on both the flow and return pipe connections ensure clip is oriented to correctly match connecting pipe diameters Ensure the trap siphon is filled with water Refer to Frame 56 Refill the boiler Refer to Frame 22 Check operation of the boiler Refer to Frame 36 55 SERVICING SERVICING 56 SERVICING 73 EXPANSION VESSEL RECHARGING amp REPLACEMENT RECHARGING Refer to Frame 45 Remove the charge point cover Re assemble in reverse order 1 2 3 Recharge the tank pressure to 0 75 bar 4 5 Check operation of the boiler Refer to Frame36 REPLACEMENT Refer to Frame 45 Drain the boiler CH circuit Refer to Frame 60 Unscrew the union nut on the vessel water connection pipe Support the expansion vessel and unscrew the 2 screws from the securing clamp located on the top of the boiler and remove Note the position of the bracket on the vessel 10 Remove the expansion vessel 11 Fit the new expansion vessel 12 Reassemble in reverse order 13 Refill the boiler Refer to Frame 22 14 Check operation of the boiler Refer to Frame 36 74 BOILER SEALING PANEL SEAL REPLACEMENT Refer to Frame 45
29. INSTALLER Remove the Return Thermistor from the CH Return Pipe and disconnect the wires Check the resistance using a suitable multimeter Fit a new Thermistor connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 Ohms At 60 C expect 2 400 2 600 Ohms At 85 C expect 1 000 1 100 Ohms Is the Thermistor value correct Check and replace wiring as necessary Is there continuity between the PCB and the Thermistor Replace PCB 83 OUTSIDE SENSOR FAULT CONTACT INSTALLER NO Securely connect the wiring at both the Is the wiring securely connected at both the boiler and b il erand Outside concer Outside Sensor Disconnect the wires to the outside sensor Check the resistance using a suitable multimeter connected across the Outside Sensor s terminal pins Fit a new Outside Sensor AtO C expect 31 000 35 000 Ohms At15 C expect 15 000 16 500 Ohms At 30 C expect 7 700 8 500 Ohms Is the Outside Sensor value correct Securely connect the wiring at the Terminal Block and the PCB Is the wiring securely connected between the incoming terminal block boiler connection of the Outside Sensor and the PCB YES Replace PCB Keston Combi Installation and Servicing 61 O Z A Z LL J x LL O Z A Z LL 3 q LL O Z A Z LL H x LL O Z A LL H lt LL O Z A LL J lt LL FAULT FINDING 84 FLOW THERMISTOR FAULT CONTACT INSTALLER Is the wiring s
30. OP side up as shown A A UN NY CEEE Ve ASS ji hN hik kill u E vel elas Td 1 PUN Vj Feat k L L NT T q FD ror iv P sgl ae i E ase is 85 ios x Jee a RA id iit AINI Wea x v f i _ gt gt w n s s IN jag bs pma ant Se Prd 1 gt ea we w 2 8 Ribbon Cable Connection Keston Combi Installation and Servicing 47 SERVICING SERVICING SERVICING 58 USER CONTROL PCB REPLACEMENT Note Fit the earth strap provided with the PCB to your wrist and a suitable earth on the boiler chassis 1 Refer to Frame 45 2 Remove the main PCB refer to Frame 57 3 Unclip the PCB and lift to clear the mounting posts 4 Fit the new PCB ensuring the 4 potentiometer spindles line up with the control knobs which must be in a vertical position Reassemble in reverse order 6 Check operation of the boiler Refer to Frame 36 Alber gt 34338889 CUI KM721 I3 3G Be ont 2009 JUNE 18 Control Knobs to be in vertical position off on K N S lt s hot water central heating 59 DHW FLOW TURBINE SENSOR REPLACEMENT Refer to Frame 45 Remove condensate trap siphon Refer to Frame 56 Lift off the flow turbine sensor plastic retaining clip Unplug the electrical connection and transfer to new turbine sensor 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frame
31. RIDGE REPLACEMENT FRONT CARTRIDGE REPLACEMENT REAR CARTRIDGE REPLACEMENT 1 Refer to Frame 45 1 Refer to Frame 45 2 Drain the boiler Refer to Frame 65 2 Drain the boiler Refer to Frame 60 3 Remove the diverter valve head Refer 3 Remove the diverter valve head Refer to Frame 55 to Frame 55 4 Remove the flow pipe Refer to Frame 22 no 12 4 Unscrew the top connection to access 5 Disconnect the CH flow pipe and DHW outlet pipe union connections underneath the internal cartridge the boiler Refer to Frame 60 5 Fit the new valve mechanism ensuring 6 Remove the plate heat exchanger LH fixing screw Refer to Frame 66 the correct fit of the pin 7 Remove the screw retaining the brass block to the bottom of the boiler casing 6 Reassemble in reverse order and lift the brass block clear of the boiler 7 Refill the boiler Refer to Frame 22 8 Check operation of the boiler Refer to Frame 36 8 Unscrew the rear cartridge connection 9 Fit the new valve mechanism ensuring the correct fit of the pin 10 Reassemble in reverse order 11 Refill the boiler Refer to Frame 22 12 Check operation of the boiler Refer to Frame 36 FRONT CARTRIDGE REAR CARTRIDGE Keston Combi Installation and Servicing 51 SERVICING SERVICING SERVICING Refer to Frame 45 Drain the boiler Refer to Frame 60 Remove condensate trap siphon Refer to Frame 56 Remove the diverter valve actuator Refer to Frame
32. T PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 79 LOW WATER PRESSURE 1 FILL SYSTEM TO 1 0 BAR 2 BLEED RADIATORS 3 CONTACT INSTALLER Are the Boiler and CH System filled with water and Fill and vent the system and open all isolation valves all isolation and radiator valves open check pressure gauge is between 1 to 1 5 bar i Are connections on water pressure sensor secure Refi connections Replace water pressure sensor O Z a LL x LL O Z A LL x LL O Z A LL z x LL O Z A LL H lt LL O Z A LL J lt LL Keston Combi Installation and Servicing 59 FAULT FINDING 80 FLAME LOSS 1CHECK OTHER GAS APPLIANCES WORK 2 CONTACT INSTALLER Does the boiler ignite for a short Is the Gas Pressure available at Check gas supply and time and then extinguish the Boiler Inlet 18 mbar rectify fault Check the detection electrode and Is 215Vdc supply available at the Check wiring from gas associated harness for continuity Gas Valve while the flame is on valve to PCB for continuity visual condition and position Refer See note If the wiring is OK then to Frame 52 Check if condensate replace the PCB pipe is blocked Check if flue is blocked Replace as necessary Check spark generator and associated harness for continuity Replace Spark Generator and visual condition Refer to and Harness as ne
33. Temperature Control to the two LH connections of the terminal block as shown Re assemble in reverse order Keston Combi Installation and Servicing Programmable Room Stat Programmable Optional Frost Stat Optional Frost Stat 3G9990a 29 INSTALLATION INSTALLATION Jelsouui u WOOY uonesuedwoy JEJSOWIOY L ul ulu do J U e AA n jJ A EA JEW AJ9S 1O O uuoo p01 99 4 SIAJ S B A JOSUBS JOSu S um gn Swag Jo sIUUAY uo jsiuu u S1nss d Mol S Afd WIN ay MO 4 aS TEN JEN qjq yq I B 49 IJE yg ES i i 1 d yq zq 3 B A J Uu B yq Iq q yeyg_ ddng S Wwooy Uen SO1d yeg m 2 ren O m en Q m O m u E ME e mz Tt LULL EIT Pee Peper rey JOJOIA A e6uelo JO Koi6 5 UsaJB MoOj aA B OHYUM M NO J yud d pol J UMOJG JQ yoe q q nq q AJM Z 30 WIRING DIAGRAM OILY T IV LSNI Keston Combi Installation and Servicing 30 INSTALLATION 31 COMMISSIONING AND TESTING A Electrical Installation 1 Checks to ensure electrical safety should be carriedoutbya 4 competent person 2 ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable test meter 3 After wiring the boiler all grommets in the bottom panel MUST B Gas Installation The whole of the gas ins
34. Thermostat 112 Diverter Valve Cartdrige 203 Gas Cock 231 Condensate Outlet Connection 401 Heat Engine 113 Pressure Relief Valve 204 Pipe Gas Inlet 301 Ctrs Box Fixings Hinge amp Spring 503 Wall Mounting Bracket 114 Pipe PRV Outlet 205 Gas Valve 302 Primary PCB 504 Front Panel 115 Pipe Flow 206 Pipe Gas Injector 303 CUI Board 505 Seats 116 Pipe Return 211 Injector Assembly 304 Control Thermistor Return 205 Bracke Gas valve 117 Pipe Expansion Vessel 214 Venturi 306 Electrode Ignition q sS ee 118 Expansion Vessel 215 Fan 307 Electrode Detection 136 Safety Valve Drain Pipe 119 Return Group Manifold 247 Burner 308 Igniter Unit 512 Drop Down Door 332 Flue Thermostat Note that production boiler PCBs are factory pre set to operate for boiler range and output When ordering Primary PCB as a spare an additional Boiler Chip Card BCC MUST also be purchased for your specific boiler range and output 227 Check boiler serial letter code on data 224 plate to obtain correct BCC ry te N LL F lt 4 D 12 Keston Combi Installation and Servicing 7 UNPACKING Unpack and check the contents Pack 1 Contents Boiler Hardware Pack Box Wall Mounting Plate These Installation Instructions Wall Mounting Template located on internal protective packaging mo O U gt 7 Turret Clamp G Safety Valve Drain Pipe H Boiler Guarantee Registration pack HARDWARE PACK CONTENTS Gas Valve Pa
35. Total Hardness as defined by BS 7593 2006 Table 2 a scale heat exchanger reducing device should be fitted into the boiler cold supply within IMPORTANT the requirements of the local water company The use of artificially The application of any other treatment to this product softened water however is not permitted may render the guarantee of Keston Invalid Keston recommend the use of Fernox Quantomat Sentinel Combiguard or Calmag CalPhos scale reducing devices together with scalemaster in line scale inhibitor branded Ideal which must be used in accordance with the manufacturers instructions Keston recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems If water treatment is used Keston recommend only the use For further information contact of SCALEMASTER GOLD 100 FERNOX MBI ADEY MC1 or Fernox Cookson Electronics SENTINEL X100 inhibitors and associated water treatment Forsyth Road Sheerwater Woking Surrey GU21 5RZ products which must be used in accordance with the 44 0 870 601 500 manufacturers instructions Sentinel Performance Solutions Notes The Heath Business amp Technical Park Runcorn Cheshire WA7 4QX Tel 0800 389 4670 1 Itis most important that the correct concentration of the Www sentinel solutions net water treatment products is maintained in accordance with the manufacturers instructions Scalemaster Water Treatment Products
36. W at approximately 64 C with the DHW temperature control knob set to maximum 4 Close the DHW tap and check that the main burner extinguishes The pump should overrun for 60 seconds during which the boiler will display Pump overrun The fan will then continue to run for a further 3 minutes during which the boiler will display Fan Post Purge after which the boiler will display one of the following Standby mode Summer mode Winter Mode depending on the position of the mode knob Note On systems in excess of 2 bar inlet pressure a water pressure governor may be required to prevent water noise WATER CIRCULATION SYSTEM 1 With the system COLD check that the initial pressure is correct to the system design requirements For pre pressurised systems this should be 1 0 bar 2 With the system HOT examine all water connections for soundness The system pressure will increase with temperature rise but should not exceed 2 5 bar 3 With the system still hot turn off the gas water and electricity supplies to the boiler and drain down to complete the flushing process Note A flushing solution should be used during the flushing procedure Flushing solutions Fernox Superfloc Sentinel X300 new systems or X400 existing systems Refer to Frame 5 4 Refill and vent the system add inhibitor see Frame 5 Clear all air locks and again check for water soundness 5 Reset the system initial pressu
37. al soil vent stack see Fig 4 Insulation measures as described should be used When a rainwater downpipe is used an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe become flooded or frozen see Fig 5 Where the condensate drain pipe terminates over an open foul drain or gully the pipe should terminate below the grating level but above water level to minimise wind chill at the open end The use of a drain cover as used to prevent blockage by leaves may offer further prevention from wind chill See Fig 6 Where the condensate drain pipe terminates in a purpose designed soak away see BS 6798 any above ground condensate drain pipe sections should be run and insulated as described above See Fig 7 Unheated Internal Areas Internal condensate drain pipes run in unheated areas e g lofts basements and garages should be treated as external pipe Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual Figure 2 Connection of a Condensate Drainage Pipe Downstream of a Sink Basin Bath or Shower Water Trap to Internal Soil Vent Stack Boiler with 75mm sealed condensate Min 19mm Internal pipe Sink basin bath or shower x oO J N g gt o ro Z pa Boilers without 7
38. and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer name Telephone number Address Boiler make and model Boiler serial number Commissioned by PRINT NAME Gas Safe register number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating f Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions What system cleaner was used What inhibitor was used Quantity litres Has a primary water system filter been installed Yes No CENTRAL HEATING MODE measure and record
39. ap is refilled with water before reassembling 9 Check the gas consumption 10 Check combustion by connecting the flue gas analyser to the flue gas sampling point as shown in the diagram and measure CO amp a If the CO CO ratio is greater than 0 004 AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure and gas rate have been verified then contact Keston 11 Complete the service section in the Benchmark Commissioning Checklist Keston Combi Installation and Servicing 37 SERVICING SERVICING SERVICING 39 BOILER FRONT PANEL REMOVAL REPLACEMENT REMOVAL 1 Loosen the two screws retaining the front panel 2 Pull the two spring clips down to disengage and pull panel forward and upward and remove REPLACEMENT Hook the panel onto the top retaining clips Push the panel until the 2 bottom spring clips engage ensuring the 4 control knobs line up with the holes in the front panel Re tighten the two retaining screws view from bottom of boiler view from top of boiler 40 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING Disconnect the electrical leads from the fan Undo the gas pipe union connection to the injector housing Remove the extended nut on the fan mounting bracket 4 Lift off fan and venturi assembly 5 Inspect the injector for blockage or damage 6 Inspect fan outlet sealing gasket and replace if necessary
40. appliance pump to assist venting of the air this must be done with the gas service cock turned off 2 Refit the boiler front panel Refer to Frame 39 3 Check that the drain cock is closed and that the CH and DHW isolating valves M L and G are OPEN Check that the electrical supply is OFF Check that the boiler mode control knob D is off Check that the gas service cock K is OPEN Slacken the screw in the inlet pressure test point J and connect a gas pressure gauge via a flexible tube SS Ss 8 Switch the electricity supply ON and check all external controls are Calling for heat CENTRAL HEATING 9 Setthe CH temp control C to max and turn the mode control knob D to ensure the timer room stat are on The boiler control will now go through its ignition sequence until the burner is established 10 If the boiler does not light the following messages will be displayed in rotation Ignition Lockout 1 Check other gas appliances 2 Reset boiler 3 Contact installer After 5 attempts the boiler will lock out and carry on displaying the messages Reset the boiler refer to Frame 40B The boiler will repeat its ignition sequence If reset occurs 5 times within 15 minutes then Too many resets will be shown If power is removed this will be reset When the burner is established the BLUE Burner On neon F will be illuminated the LCD will display Central Heating and Radiato
41. ave been certified by a notified body Note Gas consumption is calculated using a Key to symbols calorific value of 38 7 MJ m 1038 Btu ft gross l l or 34 9 MJ m 935 Btu ft nett PMS Maximum operating pressure of water C G A room sealed appliance designed for connection via ducts to To obtain the gas consumption at a different ip a horizontal terminal which admits fresh air to the burner and calorific value discharges the products of combustion to the outside The fan is a For l s divide the gross heat input up stream of the combustion chamber kW by the gross C V of the gas MJ m a l An appliance designed for use on 2nd Family gas Group H only b For ft h divide the gross heat input Btu h by the gross C V of the gas Btu ft c For m h multiply I s by 3 6 4 Keston Combi Installation and Servicing GENERAL CONTENTS KESTON Combi 30 amp 35 Natural Gas onl y Benchmark Commissioning Checklist Boiler size Boiler Clearances Benchmark No Boiler Exploded Diagram 86 CL 38 Condensate Drain 86 CL 38 Electrical Connections Electrical Supply Fault Finding Flue System Gas Safety Regulations Gas Supply Installation Safe Handling Servicing Short List of Parts Thermostatic Radiator Valves Water and Systems Water Connections Water Treatment Wiring Diagram For GB to comply with Building Regulations Part L1 Part 6 in Scotland the boiler should be fitted in accordance wi
42. boiler For the minimum clearances required for safety and subsequent service see the wall mounting template and Frame 1 In addition sufficient space may be required to allow lifting access to the wall mounting plate The boiler must be installed on a fire resistant surface GENERAL GAS SUPPLY The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must NOT be used without prior consultation with the local gas supplier The boiler MUST be installed on a gas supply with a governed meter only A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer In IE by a Registered Gas Installer RGII An existing meter should be checked preferably by the gas supplier to ensure that the meter is adequate to deal with the rate of gas supply required It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS6891 2005 Whilst the principle of the 1 1 gas valve ensures the Keston Combi range is able to deliver its full output at inlet pressures as low as 14mb other gas appliances in the property may not be as tolerant When operating pressures are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation Allowing for the acceptable pressure loss of 1mb a
43. cessary Frame 53 Are these functioning correctly Replace Ignition Electrode and associated harness as necessary Check ignition electrode and associated harness for continuity visual condition and position Refer to Frame 51 Are these functioning correctly i NO Check siphon and condensate Replace Gas Valve drain pipe work for blockage and rectify if necessary Boiler now working OK Clear obstruction Ensure wiring correctly connected Check flue temperature always remains below 90 C Replace Thermostat Check if burner is Replace burner damaged Replace heat exchanger Note due to the wave form of the rectified voltage the reading will vary depending on the type of meter used to measure the value In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve Check wiring to thermostat O Z A LL H lt LL O Z A LL J lt LL O Z A LL J lt LL O A LL J lt LL O A LL lt LL 60 Keston Combi Installation and Servicing FAULT FINDING 81 FAN FAULT CONTACT INSTALLER Does the wiring from the Fan to the PCB have secure connections at both ends and has not Rectify Wiring amp deteriorated Does the wiring have continuity connections Replace PCB Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan Replace Fan 82 RETURN THERMISTOR FAULT CONTACT
44. ck 1 Pipe Gas Inlet 2 Washer Gas blue 3 Gas Cock Filling Loop Pack 1 3 8 Fibre washer x4 2 Valve double check valve fitting 3 Valve Filling Loop 4 Plastic Chain x2 5 Filling Loop 6 3 8 Blanking Rubber Washer x2 Return Valve Pack 1 Pipe CH Return 2 Washer CH 3 Valve Return DHW Pack 1 Pipe DHW Outlet 2 Valve Return DHW 3 Washer DHW x2 4 Pipe DHW Inlet 5 Nut 1 2 Accessory Pack 1 Screw x2 2 Wallplug x2 3 Turret Clamp Screw x1 Flow Valve Pack 1 Pipe CH Flow 2 Washer CH 3 Valve Flow with gauge Flue Pack Contents Flue Adaptor Air Spigot Terminals 2 off Flue Sleeve Wall Plate Wall Seal Outside Sensor Screws 4 off Wall Plugs 4 off c T O TI IT O O gt Keston Combi Installation and Servicing INSTALLATION Gas Valve Pack oe OO Filling Loop Return Valve Pack O DHW Pack O E mm Bin Oo ow oe Accessory Pack ijo Flow Valve Pack
45. cross the installation pipework it can be assumed that a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance Reference BS 6400 1 Clause 6 2 Pressure Absorption The external gas cock could further reduce the operating pressure when measured at its test point The pressure drop is relative to the heat input to the boiler kW refer to graph below Gas Cock Pressure Drop a a E 2 2 T 3 un un s 1 0 0 5 0 10 0 15 0 200 25 0 30 0 heat input to boiler KW 32 0 400 45 0 IMPORTANT Installation pipes must be fitted in accordance with BS 6891 In IE refer to 1S 813 2002 The complete installation MUST be tested for gas tightness and purged as described in the above code WATER CIRCULATION SYSTEM IMPORTANT A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping The central heating system should be in accordance with BS 6798 and in addition for smallbore and microbore systems BS 5449 WATER TREATMENT see Frame 5 BOILER CONTROL INTERLOCKS Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating in compliance with Building Regulations Heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the
46. de knob to the standby position Diverter valve DHW position 3G9714 35 RESET PROCEDURE To reset boiler turn the mode control knob D to reset position and immediately turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present off on AN off ae ee HNO G min max min max reset preheat E water Central heating mode A B F C D Legend A Pre heat On off D Off Summer Winter Reset Control B DHW temperature control E Boiler Status C CH temperature control F Burner on indicator 34 Keston Combi Installation and Servicing INSTALLATION 36 GENERAL CHECKS Make the following checks for correct operation in DOMESTIC HOT WATER DHW MODE 1 Fully open all DHW taps in turn and ensure that water flows freely and that the mode knob is either in summer or winter position The boiler will display Hot Water Efficiency Temperature XX C High where the temperature shown is the current Domestic Hot Water temperature When the burner is lit the light above the display will be on 2 Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate This is factory set to give a DHW temperature rise of approximately 35 C at the flow rate stated on page 6 under operation 3 Reduce the DHW draw off rate to about 3 I min 0 7gpm and check that the boiler modulates to deliver DH
47. e adjusted using the Central Heating Temperature Control Knob on the boiler as follows Essentially rotating the knob clockwise increases the room temperature and rotating the knob anti clockwise decreases the room temperature If the Central Heating Temperature Control Knob is rotated fully clockwise then for an Outside Temperature of 15 C a Flow Temperature of 40 C will be provided For an Outside Temperature of 0 C a Flow Temperature of 78 C will be provided with the relationship varying lineally in between these 2 points line on the graph 2 5 If the Central Heating Temperature Control Knob is in its mid position then for an Outside Temperature of 15 C a Flow Temperature of 36 C will be provided For an Outside Temperature of 0 C a Flow Temperature of 65 C will be provided with the relationship varying lineally in between these 2 points line on the graph between 1 6 and 1 8 If the Central Heating Temperature Control Knob is rotated fully anti clockwise then for an Outside Temperature of 15 C a Flow Temperature of 30 C will be provided For an Outside Temperature of 0 C a Flow Temperature of 44 C will be provided with the relationship varying lineally in between these 2 points line on the graph 1 0 28 Keston Combi Installation and Servicing INSTALLATION 29 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler The fuse rating should be 3A Wiring external to the boiler MUST be in accordance with the current I E E
48. e appliance it is recommended that it is checked at regular intervals and serviced as necessary The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually It is the law that any service work must be carried out by a Gas Safe Registered Engineer In IE service work must be carried out by a Registered Gas Installer RGII INSPECTION GENERAL 1 Light the boiler and carry out a pre service check noting any Please Note During routine servicing and after any operational faults maintenance or change of part of the combustion 2 Check the flue terminal and terminal guard if fitted is undamaged circuit the following must be checked and clear of any obstruction The integrity of the flue system and the flue seals 3 Check all water and gas joints for signs of leakage Remake any The integrity of the boiler combustion circuit and suspect joints ensuring a gas tightness check is carried out if the relevant seals applicable and the water system is correctly refilled vented and The operational working gas inlet pressure at re pressurised maximum rate CLEANING PROCEDURE The gas rate Note In order to carry out either servicing or replacement of The combustion performance components the boiler front panel must be removed Refer to Frame 39 COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE Please Note BS 6798 2009 Specification for installation and maintenance
49. ecurely connected to the Flow Thermistor Securely connect the wiring to the Flow located in the top of the Heat Exchanger Thermistor l T l Fit a new Thermistor Disconnect the wiring from the Flow Thermistor Check the resistance using a suitable multimeter connected across the Thermistor s terminal pins Is the wiring securely connected to the low At 25 C expect 9 700 10 300 Ohms voltage 6 way connector at the front left hand At 60 C expect 2 400 2 600 Ohms side of the PCB At 85 C expect 1 000 1 100 Ohms YES NO Is the Thermistor value correct Replace PCB Securely connect the wiring to the PCB 85 BOILER CHIP CARD FAULT CONTACT INSTALLER Is the correct BCC for the boiler securely inserted into the Securely attach the BCC for the boiler onto slot at the front left of the PCB the PCB and after switching power on and c0 identified by the label on the BCC being shown reset the boiler Note Ensure the correct orientation of BCC by placing TOP side up Replace the BCC with a new BCC that is correct for the boiler After switching power on and cO being shown YES reset the boiler Is c2 still shown Replace PCB RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 86 NO CH OPERATION BUT DHW WORKS OK Is the mode knob in the Winter position Move the mode knob to the Winter position YES NO Are the Timer and the Room Thermos
50. ed downwards OPERATION With no demand for CH the boiler fires only when DHW is drawn off or periodically for a few seconds without any DHW draw off in order to maintain the DHW calorifier in a heated condition This only occurs if pre heat knob is in the ON period When there is a demand for CH the heating system is supplied at the selected temperature of between 45 C and 83 C until DHW is drawn off The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw off of 30 12 4 l min at 35 C temperature rise 35 14 5 I min at 35 C temperature rise When using the outside sensor provided please refer to page 27 The DHW draw off rate specified above is the nominal that the boiler flow regulator will give Due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap At low DHW draw off rate the maximum temperature is limited to 64 C by the modulating gas control The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating and performance of key components to aid commissioning and fault finding 6 SAFE HANDLING This boiler may require 2 or more operatives to move it to its installation site remove it from its packaging base and during movement into its installation location Manoeuvring the boiler
51. efer to Frame 45 Drain the boiler Refer to frame 60 Remove the expansion vessel Refer to Frame 73 Firstly increase access area by disconnecting the 22mm pipe connection at top of pump chamber and bottom of heat exchanger and remove pipe Refer to Frame 62 no s 5 6 amp 7 The automatic air vent head is retained in the pump body with a bayonet connection The air vent head and float assembly is removed by turning the head anti clockwise viewed from above and pulling upwards Reassembly is the reverse of the above Ensure the air vent head o ring seal is in place when refitting and the new ring is fitted to the return pipe top connection 7 Ensure the air vent cap is loose 8 Refill the boiler Refer to Frame 22 Check for leaks 50 around the new air vent joint Check the operation of the boiler Refer to Frame 36 Keston Combi Installation and Servicing SERVICING 64 DHW FLOW TURBINE CARTRIDGE REPLACEMENT 1 Refer to Frame 45 2 Drain the boiler Refer to Frame 60 3 Remove condensate trap siphon Refer to Frame 56 Remove the DHW flow turbine sensor Refer to Frame 59 Unscrew the top connection to access the internal part Fit the new turbine cartridge Refit the turbine flow sensor Reassemble in reverse order Refill the boiler Refer to Frame 22 10 Check operation of the boiler Refer to Frames 36 65 DIVERTER VALVE INTERNAL CART
52. egister No Telephone No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 05 Signature SERVICE 06 Engineer name Company name Engineer name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 07 Signature SERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 09 Signature SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature Signature Allinstallations in England a
53. es added Flowchart for CO Level and Combustion Ratio Check on Commissioning a Condensing Boiler Keston reserve the right to vary specification without notice Keston Combi Installation and Servicing 3 GENERAL Table 1 General Data Keston Combi _ 3 3 Inlet Connection DHW 15mm copper compression Maximum Working Pressure Sealed Systems bar Ib in2 External 3 Internal T4H HRC L250 V DHW ire ga Packaged Weigh g b Required for maximum flow rate Boiler operates down to 2 l min DHW delivery In areas of low water pressure the DHW restrictor can be removed Table 2 Performance Data Central Heating Table 3 Performance Data Domestic Hot Water Boiler Input Min 30 Min 35 Nett CV 30 4 35 4 82 900 20 700 24 100 Gross CV kW 33 7 39 3 134 200 115 000 Btu h 92 000 23 000 26 900 Gas Consumption 3 135 3 658 Gas Consumption 2 512 0 623 0 734 89 22 25 9 Maximum kw 30 3 353 Boiler Output DHW Output Btu h Non Condensing 24 2 i DHW Flow Rate l min 12 4 14 5 70 C Mean Water temp 82 600 at 35 C temp rise gpm Condensing 25 6 f DHW Specific Rate l min 14 5 16 9 40 C Mean Water temp 87 400 gpm Seasonal efficiency SEDBUK 2005 91 1 91 SEDBUK 2009 89 88 9 NOx Classification CLASS 5 F The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated h
54. ess of 30 C the Differential now below 20 C NO YES Check the Return Thermistor Refer to Frame 49 Replace the Pump OK now Check resistance using a suitable multimeter then reset boiler reset boiler connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 Ohms At60 C expect 2 400 2 600 Ohms RESET PROCEDURE To reset boiler turn mode knob to reset At 85 C expect 1 000 1 100 Ohms position and immediately turn knob back to required setting 77 IGNITIONLOCKOUT FLUE OVERHEAT 1 CHECK OTHER GAS APPLIANCES WORK 2RESET BOILER 3 CONTACT INSTALLER If the boiler is reset does the boiler ignite NO Is the Gas Pressure available at NO Check gas supply and for a short time and then extinguish the Boiler Inlet gt 18 mbar rectify fault Is approx 215Vdc supply available Check wiring connection at the Gas Valve See note Check the detection electrode and associated harness for continuity continuity If the wiring is OK then replace the PCB s unn Replace Gas Valve Check spark generator and associated harness for continuity and visual Replace Spark condition Refer to Frame 53 Are Generator and harness these functioning correctly as necessary visual condition and position Refer to Frame 52 Check if the condensate pipe is blocked Replace as necessary Unplug gas valve Is resistance between outside pins 4KQ 2 Check ignition electrode and associated harness for conti
55. et every Er eel a bag Air Pipe Length m 1 metre FLUE OUTLET 16 1 5 back 2m 2 5m to boiler HO L Air Flue 4 x 90 elbows 4 Straight lengths 2 2 3 5 444444444444444444444444444444444444441414144 4 0 15 15 65 Overall Flue Air 30 15m 3 x 90 elbows Straight lengths Acceptable Operating Area 14 16 4 6 8 10 12 18 20 22 24 26 28 Flue Pipe Length m Keston Combi Installation and Servicing INSTALLATION 12 FLUE TERMINATION POSITION Twin Flue Positions Flue Minimum Spacing Air Minimum Spacing A Below an opening 1 B Above an opening 1 300 mm gutters soil pipes or drain pi E Beloweves 200mm 8 som _ 2 F Below balcony or car port roof 200mm 8 5mm G Froma vertical drain pipe or soil pipe o o 150m 50mm 2 M Vertically from a terminal on the samewall 1500mm 60 1500mm 6 1 An opening here means an openable element such as a openable window or a fixed opening such as an air vent However in addition the outlet should not be nearer than 150mm fanned draught to an opening into the building fabric formed for the purpose of accommodating a built in element such as a window frame The dimensions given in the table above may need to be increased to avoid wall staining and nuisance depending on site conditions boundary boundary ey Z w w m m m w GENERAL INSTALLATIONS All parts of the system must be constructed in acc
56. flow temperature return temperature domestic hot water temperature DHW flow rate and diverter valve position Next the boiler will display Venting Boiler OFF Now move the pre heat knob and the Air Venting Function will begin the boiler will display Venting Boiler Off Pump and Diverter Valve Cycling Duration 5 mins Reset to End For Activation change Pre heat Mode As part of the commissioning process the combustion of this appliance must be checked and the Benchmark Checklist completed A flow chart to assist is provided on page 71 ATTENTION IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE Keston Combi Installation and Servicing 31 INSTALLATION INSTALLATION INSTALLATION 32 INITIAL LIGHTING Legend Pre heat On off DHW temperature control CH temperature control Off Summer Winter Reset Control Boiler Status Burner on indicator CH Flow lsolating Valve Pressure Gauge Gas Inlet Pressure Test Point Gas Service Cock DHW Inlet Valve CH Return Isolating Valve DHW Outlet Z 2rxezroammoaoop 1 Check that the system has been filled and that the boiler is not airlocked Ensure the automatic air vent cap is open Refer to Frame 22 Note It is important the burner is not operated before the system is fully vented of air If it is necessary to operate the
57. for the first time or after maintenance All condensate pipework should conform to the following a Where a new or replacement boiler is being installed access to an internal gravity discharge termination should be one of the main factors considered in determining boiler location b Plastic with push fit or solvent connections c Internal plastic pipe work a minimum of 19mm ID typically 22mm OD d External plastic pipe must be a minimum of 30mm ID typically 32 OD before it passes through the sleeved wall e All horizontal pipe runs must fall a minimum of 45mm per metre away from the Boiler f External amp unheated pipe work should be kept to a minimum and insulated with Class O waterproof pipe insulation g All installations must be carried out in accordance to the relevant connection methods as shown in the Condensate installation diagrams amp BS6798 2009 h Pipe work must be installed so that it does not allow spillage into the dwelling in the event of a blockage through freezing i All internal burrs should be removed from the pipe work and any fittings In order to minimise the risk of freezing during prolonged very cold spells one of the following methods of terminating condensate drainage pipe should be adopted Internal Drain Connections Wherever possible the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an interna
58. fully drained before cleaning Refer to Frame 61 Ignition Electrode Flame Detection ee K M Remove ignition and flame detection electrodes Refer to Frames 51 amp 52 It is advisable to replace the sump cover prior to the water flush process Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the full top area is covered Remove the sump cover and clean loose deposits from the sump Inspect the ignition and detection electrodes Ensure that they are clean and in good condition replace if necessary Re fit the ignition and flame detection electrodes ensuring that both earth tabs are fitted to ignition electrode Check that the ignition and detection gaps are correct Refer to Frames 51 amp 52 44 REASSEMBLY Reassemble the boiler in the following order Ensure that the condensate trap siphon is full of water Refit the burner ensuring the sealing gasket is correctly positioned and free from damage tighten the 4 fixing screws in the sequence shown below Refit the fan venturi assembly ensuring the retaining tabs are correctly positioned and the sealing gasket is correctly positioned and free from damage 4 Reconnect the fan electrical leads 5 Remove the sump cover and refit the lower flue manifold as 40 shown 6 Refit the sump cover Refit the boiler front panel IMPORTANT Ensure that the boiler f
59. he boiler Refer to Frame 36 a ee TO hl Y wy I s O ime SY Mm yp Di ESO TJ TE Q Hi QT 3G9690 Keston Combi Installation and Servicing SERVICING 57 MAIN PCB REPLACEMENT Note Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis 1 Refer to Frame 45 8 Re connect all plug connections 2 Note the control knob positions 9 Reassemble in reverse order 3 Remove the 2 screws retaining the control box cover 10 Turn power back on to the boiler after a few moments the 4 Carefully lift the 4 retaining clips and remove control box display will start alternating between c and 0 Turn the cover reset knob fully clockwise and when the display shows 5 Unplug all lead connections to the PCB including the ribbon en nese M ua ARAE EE R cable to facilitate ribbon cable removal ease side clips Finally move the knob into the required position Standby apart and pull upwards also where applicable push the Summer or Winter small plastic clip with an electrical screwdriver to facilitate 11 Check operation of the boiler Refer to Frame 36 plug removal 6 Spring out the two side retaining clips and pull the PCB upwards to clear the 4 corner retaining posts 7 Take the new Primary PCB and attach the appropriate Boiler Chip Card BCC Note Ensure the correct orientation of BCC by placing T
60. iler Refer to Frame 36 Spark Generator 54 GAS CONTROL VALVE REPLACEMENT Refer to Frame 45 Unplug the electrical plug connection from the gas control valve and disconnect the earth wire Undo the union nut on the outlet of the gas control valve Undo the gas inlet pipe union at the inlet to the gas control valve Loosen the back nut retaining the valve to the bracket and withdraw the valve forwards Fit the new gas control valve ensuring the two sealing washers are in place and reconnect gas and electrical connections Check operation of the boiler Refer to Frame 36 Keston Combi Installation and Servicing 45 SERVICING SERVICING 46 SERVICING 55 DIVERTER VALVE ACTUATOR REPLACEMENT Refer to Frame 45 Remove the electrical plug 3 Using a suitable tool pull out the retaining clip and lift the diverter head from the brass body Fit new actuator head and reassemble in reverse order Check operation of the boiler Refer to Fiame 36 Diverter Valve Actuator Retaining Clip 56 CONDENSATE TRAP SIPHON REPLACEMENT Refer to Frame 45 Pull off the rubber pipe at the sump drain 1 2 3 Disconnect the condensate drain pipe 4 Turn the siphon clockwise to disengage and lift to remove Note Keep siphon upright when removing Clean siphon with water Re assemble in reverse order When re assembling ensure the trap is full of water Check operation of t
61. ing Flue Thermostat 43 SERVICING SERVICING SERVICING 51 IGNITION ELECTRODE REPLACEMENT Refer to Frame 45 Remove the burner Refer to Frame 48 Unplug the ignition lead from the electrode Ignition Electrode Remove the earth lead from the ignition electrode Remove the 2 screws holding the ignition electrode to the combustion chamber 6 Remove the electrode 7 Fit the new ignition electrode using the new gasket supplied Check dimensions as shown 8 Reassemble in reverse order Check the operation of the boiler Refer to Frame 36 Spark Gap oo lu 3 5mm 1 52 FLAME DETECTION ELECTRODE REPLACEMENT 1 Refer to Frame 45 2 Remove the burner Refer to Frame 48 3 Unplug the flame detection lead from the electrode Flame Detection Electrode Remove the 2 screws retaining the detection electrode Remove the electrode 6 Fit the new flame detection electrode using the new gasket supplied 7 Reassemble in reverse order 8 Check the operation of the boiler Refer to Frame 36 44 Keston Combi Installation and Servicing SERVICING 53 SPARK GENERATOR REPLACEMENT Refer to Frame 45 2 Disconnect the leads from the spark generator Remove the M5 screws securing the spark generator to the boiler chassis Fit the new spark generator and re assemble in reverse order ensuring the two earth leads are correctly replaced Check operation of the bo
62. l soil and vent stack or kitchen or bathroom waste pipe etc See Figs 1 and 2 Figure 1 Connection of Condensate Drainage Pipe to Internal Soil amp Vent Stack Boiler with 75mm sealed condensate Min 19mm Internal pipe Soil amp vent stack Minimum connection height up to 3 storeys Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break 22 Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc fig 3 External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soak away If an external system is chosen then the following measures must be adopted The external pipe run should be kept to a minimum using the most direct and most vertical route possible to the discharge point with no horizontal sections in which condensate might collect For connections to an extern
63. ld be loose enough on the pipe to allow thermal expansion and contraction movement Flue pipework through walls MUST be sleeved to allow thermal expansion and contraction movement Check all connections for security and re seal any joints using solvent cement where soundness may be in doubt Note It is equally important to seal the air inlet with solvent cement as the flue outlet pipe joints Keston Combi Installation and Servicing INSTALLATION 19 FITTING THE FLUE SLEEVE 1 Cut hole in wall Measure wall Thickness Cut sleeve length to match wall thickness amp remove burrs Grout sleeve into wall with flange on external face Slide flue pipe into sleeve checking it is free to slide p YS N Slide Flexible wall seal over flue pipe and push centre ring up to sleeve flange when cold 7 Locate wall plate over flexible wall seal and clamp in place using the raw plug pack 8 Affix flue terminal 9 During boiler test check that the flue end is free to expand and contract with flexible wall seal Flue Terminal Flue Pipe Flue Sleeve Flue Sleeve Flange Flexible Wall Wall Plate Seal li J 0 ll J L Keston Combi Installation and Servicing INSTALLATION INSTALLATION 20 CONDENSATE DRAIN Condensate Drain This appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance
64. lectricity Provider If PCB is a spare check Boiler Chip Card SUB Wells comedi raal BCC fitted otherwise replace PCB PCB Replaced Outside sensor fault Contact installer Reset boiler Reset the boiler Go to Frame 82 Contact installer Return Thermistor Fault Flow thermistor fault Go to Frame 85 Boiler Chip Card Fault BCC Fault Contact installer It is recommended to have the boiler serviced Reset the boiler to clear message Contact installer 12 month service interval request Go to Frame 86 No CH operation but DHW operates OK No CH operation but DHW works OK Go to Frame 87 No DHW operation but CH operates OK No DHW but CH operates OK Go to Frame 88 sO Dplay No Display O Z A LL x LL O Z A Z IL x x LL O Z A LL lt LL O Z A Z LL F lt LL O Z A LL lt LL RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting Ql Keston Combi Installation and Servicing T FAULT FINDING 76 OVERHEAT LOCKOUT 1FILL SYSTEM TO 1 0 BAR 2 BLEED RADIATORS 3 CHECK RADIATOR VALVES OPEN 4RESET BOILER 5 CONTACT INSTALLER Is the Boiler and CH System filled with water and all NO Fill and vent the system and open all isolation and radiator valves open isolation valves then reset boiler Is the Flow Return Differential across the Boiler in Check that the Pump is rotating freely Is exc
65. lling loop refer to Frame 22 before proceeding to check operation of the boiler 5 Disconnect filling loop Refer to Frame 22 6 Check operation of the boiler Refer to Frame 36 61 PRESSURE GAUGE RENEWAL Refer to Frame 45 Drain the heating system Refer to Frame N Jer mal x C x Unscrew the pressure gauge and discard _ Fit new pressure gauge using suitable jointing compound Refill the boiler Refer to Frame 22 Check operation of the boiler Refer to Frame 36 3G9690 Keston Combi Installation and Servicing 49 SERVICING SERVICING SERVICING 62 SAFETY RELIEF VALVE RENEWAL WZ Refer to Frame 45 Drain the boiler Refer to Frame 60 Remove the condensate trap siphon Refer to Frame 56 Remove expansion vessel Refer to Frame 73 5 Disconnect the electrical connection from the return thermistor Disconnect the 22mm pipe connection at the rear of the pump oullet Pull off the clip retaining the pipe to the heat exchanger swing the pipe to clear the pump and remove pipe 8 Undo the safety valve union connection Withdraw the clip securing the safety valve Lift safety valve from boiler Fit the new safety valve and reassemble in reverse order ensuring the new o ring is fitted to the top of the return pipe Refill boiler Refer to Frame 22 Check operation of boiler Refer to Frames 36 63 PUMP AUTOMATIC AIR VENT REPLACEMENT R
66. local regulations 24 INTERNAL WIRING The Keston Combi boiler comes pre fitted with 1 8m of mains cable This must be connected to a permanent live supply and NOT switched by thermostats programmers For installers wishing to change this cable refer to Frame 26 The Keston Combi boiler comes pre fitted with a link wire between the room thermostat Timer connections on the terminal strip This creates a permanent call for heat and must be removed when adding a room thermostat programmer The terminal block cover carries two spare fuses for the main PCB Spare PCB fuses Keston Combi Installation and Servicing Wiring should be 3 core PVC insulated cable not less than 0 75mm 24 x 0 2mm and to BS 6500 Table 16 For IE reference should be made to the current ETCI rules for electrical installations Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both poles The means of isolation must be accessible to the user after installation To add thermostat programmer 1 2 3 Isolate the mains supply to the boiler Remove the front panel Refer to Frame 39 Swing the control box down into the servicing position Refer to Frame 45 Route incoming cables through the grommets in bottom panel note grommets are blind and will require puncturing and secure using clamps and screws provided in hardware
67. may include the use of a sack truck and involve lifting pushing and pulling Caution should be exercised during these operations Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered e Grip the boiler at the base e Be physically capable e Use personal protective equipment as appropriate e g gloves safety footwear During all manoeuvres and handling actions every attempt should be made to ensure the following unless unavoidable and or the weight is light e Keep back straight e Avoid twisting at the waist e Avoid upper body top heavy bending e Always grip with the palm of the hand e Use designated hand holds e Keep load as close to the body as possible e Always use assistance if required OPTIONAL EXTRA KITS e Electronic Timer 7 day kit e Electronic Programmable Room Thermostat kit Stand Off kit e Air Terminal Finishing Kit e Flue Sleeve Kit Keston Combi Installation and Servicing GENERAL SAFETY Current Gas Safety installation and use regulations or rules in force The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation must be carried out by a Gas Safe Registered Engineer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation and Use Regulations The appr
68. mbi boiler is a wall mounted full sequence automatic spark ignition low water content fanned flue high efficiency condensing combination gas boiler Note Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation Central heating CH output is fully modulating with a range of 30 6 1 to 24 2kW 20 700 to 82 600 Btu h 35 7 1 to 24 2kW 24 100 to 82 600 Btu h Instantaneous domestic hot water DHW output is also fully modulating with a maximum of 30 30 3kW 103 300 Btu h 35 35 3kW 120 500 Btu h The boiler is supplied fully assembled with DHW plate heat exchanger diverter valve circulating pump pressure gauge safety valve and CH expansion vessel Variable CH and DHW temperature controls are fitted on the user control and the boiler features a DHW preheal facility The boiler includes as standard Automatic bypass Boiler frost protection Daily pump and diverter valve exercise Weather Compensation Kit The boiler casing is of white painted mild steel The boiler temperature controls are visible located in the control panel on the front of the boiler The heat exchanger is manufactured from cast aluminium The boiler is suitable for connection to fully pumped sealed heating systems ONLY Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework Pipework from the boiler is rout
69. n the frost thermostat in a suitable position i e area vulnerable to OL STAT freezing SI OPTIONAL 2 Connect frost stat across terminals marked frost stat shown in diagrams A amp B DIAGRAM C WEATHER COMPENSATION KIT Weather Compensation Kit The two wires from the weather compensation kit outside sensor must be connected into the two right hand terminals as shown in diagram C Optional Frost Stat OpenTherm Outside mal gt Harness Sensor TOL Weather gt Compensation Keston Combi Installation and Servicing INSTALLATION 26 REPLACING PRE FITTED MAINS CABLE If it is necessary to use an alternative mains cable to the one pre fitted then use the following guide Replacement wiring should comply with notes in Frame 23 Isolate the mains supply to the boiler Remove the front panel Refer to Frame 39 Swing the control box down into the service position Refer to frame 45 4 Remove the live neutral and earth wires from the terminal block Loosen the cable clamp and withdraw the mains cable Route replacement cable back through the cable clamp and grommet and re tighten to provide cord anchorage Connect the live neutral and earth wires to the terminal strip When making the mains electrical connections to the boiler it is important that the wires are prepared in such a way that the earth conductor is longer than the current carrying conductors such
70. nated and cut at 45 43mm 90 male female bend 68mm PVCU Strap on fitting Figure 7 Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away Boiler with 75mm sealed condensate trap Min 30mm Internal pipe ater Weather roof insulation Min 19mm Internal a li me eet Boilers without 75mm sealed Limestone condensate trap must be fitted with pod chippings a 75mm trap and visible air break 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Keston Combi Installation and Servicing insulation 45 pipe termination Internal sine Sink basin bath or shower with integral overflow and 75mm trap Minimum 30mm internal pip 2 25 Below grate 23 INSTALLATION INSTALLATION INSTALLATION 22 CONNECTIONS amp FILLING NOTES Ensure all boss blanking plugs are removed before connecting hardware Each valve must be fitted to the correct boss as shown in the picture Ensure each union is fitted with fibre seals provided Note The domestic hot water flow rate is automatically regulated to a maximum of 12 4l m 2 8 gpm Do not subject any of the isolating valves to heat as the seals may be damaged WATER CONNECTIONS CH 1 Connect the CH flow service valve black handle and copper tail provided in the hardware pack to the threaded boss connection provided at the lower rear of the boiler
71. nce with the Institute of Gas Engineering document IGE UP 7 2006 Edition 2 Bathroom Installations This appliance is rated IP20 The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current IEE BS 7671 Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower For IE reference should be made to the current ETCI rules for electrical installations and l S 813 2002 If the appliance is to be installed in a room containing a bath or shower then providing water jets are not going to be used for cleaning purposes as in communal baths showers the appliance must be installed beyond Zone 2 as detailed in BS 7671 Ceiling Recessed window Zone 2 3G8913a Compartment Installations A compartment used to enclose the boiler should be designed and constructed specially for this purpose An existing cupboard or compartment may be used provided that it is modified for the purpose In both cases details of essential features of cupboard compartment design including airing cupboard installation are to conform to the following e BS 6798 No cupboard ventilation is required see Air Supply for details The position selected for installation MUST allow adequate space for servicing in front of the
72. nd Wales must be notified to Local Authority Building Control LABC either directly or through a enchmar Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk 70 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory set and must not be adjusted DURING COMMISSIONING If the boiler requires conversion to operate with a different gas family e g conversion from natural gas to LPG sepa rate guidance is provided with the conversion kit supplied and this must be followed PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK The installation instructions must have been followed gas type verified and gas supply pressure gas rate checked as required prior to commissioning As part of the installation process ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidance has been followed e g Gas Safe Register Technical Bulletin TB 008 where chimney flues are in voids
73. nnected from the gas supply in accordance with GSIUR CO level less han 350ppm AND CO CO2 ratio less than 0 0040 Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Set Boiler to Minimum Gas Rate see opposite page In accordance with boiler instructions set boiler to operate at minimum rate to minimum load condition CO level less Allow sufficient time for combustion to stabilise than 350ppm AND CO COz2 ratio less than 0 0040 Check CO and Combustion Ratio at Minimum Gas Rate With boiler set at minimum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Turn off Appliance and Call Ideal Technical Helpline The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GS I amp U R NOTE Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal CO level less han 350ppm AND CO CO ratio less than 0 0040 Yes Boiler is Operating Satisfactorily No further actions required Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed Complete Benchmark Checklist recording CO and combustion ratio readings as re
74. nsor box plastic cover and screw plug the sensor body to the wall Wire a twin core 0 5mm cable from the sensor to the boiler through an RH grommet located on the underside of the boiler Cable length between sensor and boiler should be no greater than 20m Note that this connection is safety extra low voltage It is not necessary for the person carrying out the wiring to be approved to Part P of the Building Regulations Avoid running this cable alongside mains voltage cables a Wiring the Weather Compensation Kit to the Keston Combi 1 Isolate the electricity supply to the boiler 2 Remove the boiler front panel refer to boiler installation instructions 3 Hinge down the control box 4 Connect the sensor wiring into the RHS of the 4 way terminal block and secure with a cable clamp 5 Re assemble in reverse order Keston Combi Installation and Servicing 27 INSTALLATION INSTALLATION 28 CH OPERATION The On and Off time control of central heating should be controlled by a separate timer This can be a standard unit or either of the options available from Keston Combi range During programmed On times the Central Heating Radiator Flow Temperature is controlled by the boiler relative to the Outside Temperature as shown in the following diagram Weather Compensation Control Room Setpoint 20 C INSTALLATION CH Temperature Setpoint C Outside Temperature C The Room temperature can b
75. nuity visual condition and position Refer to Frame 51 Are these functioning correctly Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Replace Ignition Electrode and associated harness as necessary NO Check flue for obstruction YES Clear obstruction NO Note due to the wave form of ae Ensure wiring correctly the rectified voltage the reading Check wiring to thermostat YES will vary depending on the type NO of meter used to measure the value In general terms a reading remains below 90 5 s Replace Thermostat remains below 90 C p the correct voltage is supplied to the gas valve NO x x YES CCI US Replace burner RESET PROCEDURE To reset NO boiler turn mode knob to reset position and immediately turn Replace heat exchanger knob back to required setting 58 Keston Combi Installation and Servicing FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 78 FAULT8 CONTACT INSTALLER FALSE FLAME LOCKOUT Reset the boiler does Boiler Work OK Check routing and integrity of internal boiler wiring is OK Check condition of Flame Sense Electrode and replace if deteriorated Separate the flame detection electrode in line connector Is there continuity between the terminals pins connected to the electrode Replace Flame Detection Electrode Check routing and integrity of internal boiler wiring RESE
76. o prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions Explain the function and the use of the boiler heating and domestic hot water controls Explain that due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap It is therefore necessary to draw the users attention to the section in the Users Instructions titled Control of Water Temperature and the following statement Additionally the temperature can be controlled by the user via the draw off tap the lower the rate the higher the temperature and vice versa Explain the function of the boiler fault mode Emphasise that if a fault is indicated the boiler should be turned off and a Gas Safe Registered Engineer consulted In IE contact a Registered Gas Installer RGII Explain and demonstrate the function of time and temperature controls radiator valves etc for the economic use of the system If a timer is fitted draw attention to the timer Users Instructions and hand them to the householder 8 9 Loss of system water pressure Explain that the dial underneath the boiler indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated Explain the re pressurising procedure and if unable t
77. o re pressurise or if the pressure continues to drop a registered local heating installer should be consulted Explain boiler reset procedure refer to Frame 35 10 After installation and commissioning please complete THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS the Commissioning Checklist before handover to the customer For IE its is necessary to complete a Declaration of Conformity to indicate compliance to l S 813 2002 IMPORTANT 11 Acomprehensive service should be carried out ANNUALLY Stress the importance of regular servicing by a Gas Safe Registered Engineer In IE servicing work must be carried out by a Registered Gas Installer RGIl 12 Inform the householder of the guarantee form and the requirement to register it to receive the full benefit of the warranty Keston Combi Installation and Servicing SERVICING 38 SERVICING SCHEDULE For the very latest copy of literature for specification amp maintenance practices visit our website www keston co uk where you will be able to download the relevant information WARNING Always turn OFF the gas supply at the gas service cock and switch OFF and disconnect the electricity supply to the appliance before servicing Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927 To ensure the continued safe and efficient operation of th
78. of gas fired boilers of rated input not exceeding 70kW net advises that 1 Clean the main burner Refer to frame 41 2 Clean the heat exchanger amp condensate trap siphon Refer to Frames 41 amp 42 3 Check the main injector for blockage or damage Refer to Frame The person carrying out a combustion 0 measurement should have been assessed as 4 Check that the flue terminal is unobstructed and that the flue system competent in the use of a flue gas analyser and the is sealed correctly interpretation of the results ALSO IF THE DHW FLOW RATE IS IN QUESTION The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 5 Check the DHW filter for blockage Refer to Frame 70 and be calibrated in accordance with the analyser The cleaning procedures are covered more fully in Frames 40 45 and manufacturers requirements and MUST be carried out in sequence Competence can be demonstrated by satisfactory IMPORTANT completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS7967 Parts 1 to 4 6 After completing the servicing or exchange of components always test for gas tightness 7 When work is complete the front panel MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the boiler if the front panel is not fitted 8 If for any reason the condensate trap siphon has been removed ensure the tr
79. opriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland e The Water Fittings Regulations or Water byelaws in Scotland The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a Registered Gas Installer RGII and installed in accordance with the current edition of 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BSEN 12828 2003 Heating Systems in buildings Design for water based heating systems BSEN 12831 2003 Heating Systems in buildings Method for calculation of the design heat load BSEN 14336 2004 Heating Systems in buildings Installation and commissioning of water based heating systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW BS 6891 Low pressure installation pipes Health amp Safety Documen
80. ordance with BS 5440 Part 1 except where specifically mentioned in these instructions All pipe work must be adequately supported All joints other than approved push on or plastic compression connectors must be made and sealed with solvent cement suitable for muPVC pipes and conforming to BS 6209 1982 Consideration must be given to Corgi Gas Safe bulletin TB200 TB008 regarding flues in voids The boiler casing must always be correctly fitted to the boiler when leaving the appliance operational External wall faces and any internal faces of cavity walls must be good AIR SUPPLY The Keston Combi is a room sealed appliance and therefore does not require purpose provided ventilation to the boiler room for combustion air COMPARTMENT INSTALLATION Due to the low casing temperatures generated by the boiler no compartment ventilation is required However the cupboard or compartment must not be used for storage li a J 0 ll J L Keston Combi Installation and Servicing INSTALLATION INSTALLATION 13 INSTALLING THE BOILER Installation of the boiler is straightforward but consideration must be given to access to allow flue and air pipes to be pushed through walls and ceilings The order in which the components are installed will depend upon particular site conditions but in general it will be easiest and most accurate to install the boiler and then build up the flue outlet and air inlet pipes to the terminal this is
81. ottom sealing gasket and remove manifold Remove the 2 front fixing screws and loosen the 2 rear extended nuts Lift off the burner from the combustion chamber To facilitate the removal angle the burner as shown Fit the new burner replacing any damaged or deteriorating sealing gasket Reassemble in reverse order Refer to Frame 44 10 Check the operation of the boiler Refer to Frame 36 42 Keston Combi Installation and Servicing SERVICING 49 RETURN THERMISTOR RENEWAL Refer to Frame 44 Unclip the return thermistor from the return pipe and withdraw it from the boiler 3 Disconnect the electrical lead from the thermistor 4 Reconnect the electrical lead to the new thermistor and reassemble in reverse order ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tabs as shown Check the operation of the boiler Refer to Frames 29 35 Thermistor Locator Tab with thermistor fitted 50 FLUE THERMOSTAT REPLACEMENT Refer to Frame 45 Undo the two screws and remove the sump cover plate Disconnect the two flag terminals from the flue thermostat Lift the manifold to clear the bottom sealing gasket and remove manifold Unscrew the two M3 5 screws that connect the thermostat to the manifold Replace thermostat with new part and then refit the two screws remembering to fit rubber gasket and sealing clamp Keston Combi Installation and Servic
82. quired Keston Combi Installation and Servicing 71 Keston Heating PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 44 0 1482 443005 Fax 44 0 1482 467133 www keston co uk February 2014 UIN 207895 A03 Keston pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice
83. r Temp XX C 32 DOMESTIC HOT WATER 11 With the boiler firing set the DHW Temp Control knob B to maximum and fully open a DHW tap The boiler will continue to run and the display E will show Hot Water Temperature XX C High Efficiency 12 Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output Refer to Table 2 IMPORTANT The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan It is NOT user adjustable Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void For additional gas supply information refer to Gas Supply on page 8 13 Turn off the DHW tap Note The temperature displayed XX C is that measured at that moment not the set temperature Note The boiler incorporates a fan overrun cycle which MUST NOT be prematurely interrupted by isolation of the mains electricity supply continued Keston Combi Installation and Servicing INSTALLATION 33 INITIAL LIGHTING CONT D THE DISPLAY The user control has one neon and one display to inform the user about the status The display will show the status of the boiler The neon will show the status of the flame If no flame is detected the neon is off When the flame is detected the neon will be lit permanently The display scrolls through a maximum of 3 messages under
84. r following completion of work providing advice and assistance by phone and if necessary visiting the customer Rectify any installation problems at no cost to the customer during the installers guarantee period www centralheating co uk Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data fields on the commissioning checklist completed in full To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed The service details should be recorded on the Benchmark Service Interval Record and left with the householder DCNCHIICN COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk Heating and Hotwater Industry Council HHIC GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions
85. r head Replace turbine sensor Is Boiler DHW OK NO Change diverter Valve cartridge rear section 88 NO DISPLAY Is there 230Vac to the boiler at L and N NO Supply power to the boiler YES Is the wiring from the terminal block to the Main PCB Connect the wiring from the terminal block to the connected securely Main PCB securely Is the ribbon cable from the main PCB to the User Connect the ribbon from the main PCB to the User Interface PCB connected securely Interface PCB securely Replace the Is ribbon cable damaged User Interface PCB Replace ribbon cable O Z A LL J lt LL O Z a LL J lt LL O Z A LL J lt LL O Z A LL H lt LL O Z A LL J lt IL Keston Combi Installation and Servicing 63 SPARE PARTS When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Keston Failure to do so could affect safety or performance of this appliance Our Parts team are also available to help with your Keston Spare Parts enquiries on 01482 498665 When calling and to ensure we can provide you with the most accurate parts information please ensure you have the following to hand Boiler Model Appliance GC Number Boiler Serial Number 64 Keston Combi Installation and Servicing
86. re to the design requirement 6 Balance the system Refer to Frame 4 7 Check the condensate drain for leaks and check that it is discharging correctly Keston Combi Installation and Servicing CH amp DHW MODE 1 Ensure the CH controls are calling for heat and that the boiler mode knob is in the winter position and the CH flow temperature control knob is in the maximum position The Boiler will display Central Heating Radiator Temp XXC where the temperature shown is the current flow temperature When the burner is lit the light above the display will be on 2 Fully open the DHW tap and check that hot water is delivered The boiler will display Hot water Temperature XX C High Efficiency 3 Gas Rate Check the boiler gas rate when the boiler is at full DHW output Check at the gas meter with no other appliance in use Refer to Tables 2 and 3 for gas rates Close the DHW tap The burner should remain on and the boiler will display Central heating Radiator temp XXC 5 Set the central heating external controls to off The burner will go off and the fan and pump continue to run for 4 minutes The boiler will display Pump overrun after which the boiler will display one of the following Standby mode Summer mode Winter mode depending on the position of the mode knob 6 Check the correct operation of the timer if fitted and all other system con
87. return valve to the system fitted at least 150mm below the make up vessel on the return side of the radiators or b Where access to a make up vessel would be difficult by pre pressurisation of the system The maximum cold water capacity of the system should not exceed 143 litres if not pressurized However if the system is to be pressurized the efficiency of the expansion vessel will be reduced and a larger vessel or smaller system volume may be necessary If the capacity of the vessel is not considered sufficient for this or for any other reason an additional vessel MUST be installed on the RETURN to the boiler Guidance on vessel sizing is given in Table above Safety valve setting bar Vessel charge pressure bar 0 5 to 0 75 System pre charge pressure bar System volume litres 25 50 T5 100 125 150 175 190 200 250 300 Expansion vessel volume litres For other system volumes multiply by the factor access Water Flow Rate and Pressure Loss Max CH Output kW O eun e Water flow rate l min U rr 600 e 69 1 Head available for system m w g ftw 5 Filling The system may be filled by the following method Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling a Thoroughly flush out the whole system with cold water Fill and vent the system until the pressure gauge registers 1bar and examine for
88. ront panel is correctly fitted and that a good seal is made Swing the control box back into its working position and secure 9 Turn on the gas supply at the gas service cock 10 Reconnect the electrical supply Keston Combi Installation and Servicing SERVICING 45 REPLACEMENT OF COMPONENTS GENERAL After replacing ANY component check operation of the boiler including gas tightness gas rate and combustion test IMPORTANT Turn off the gas supply When work is complete the front panel must be correctly refitted ensuring that a good seal is made When replacing ANY component Isolate the electricity supply Remove the boiler front panel Refer to Frame 39 Notes Release the retaining clip and swing the control box down 1 In order to assist fault finding the control panel has into its servicing position an LED diagnostic display The key to boiler fault conditions is shown in Frame 75 Inorder to replace components in Frames 61 72 it is necessary to drain the boiler Refer to Frame 60 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 46 FAN REPLACEMENT gt Retaining Tabs Refer to Frame 45 2 Disconnect the electrical leads from the fan Undo the gas pipe union connection to the injector housing Remove the extended nut retaining the fan mounting bracket 5 Lift and remove the fan and venturi assembly 6 Remove the screw and twist venturi anti clockwise to
89. servicing Keston Combi Installation and Servicing 2 GENERAL SYSTEM REQUIREMENTS Central Heating Notes a The method of filling refilling topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority Antifreeze fluid corrosion and scale inhibitor fluids suitable for use with boilers having aluminium heat exchangers may be used in the central heating system General 1 3 10 The installation must comply with all relevant national and local regulations The installation should be designed to work with flow temperatures of up to 86 C All components of the system must be suitable for a working pressure of 3 bar and temperature of 110 C Extra care should be taken in making all connections so that the risk of leakage is minimised The following components are incorporated within the appliance Circulating pump b Safety valve with a non adjustable preset lift pressure of 3 bar Pressure gauge covering a range of 0 to 4 bar An 8 litre expansion vessel with an initial charge pressure of 0 75 bar Make up Water Provision must be made for replacing water loss from the system either a Fromamanually filled make up vessel with a readily visible water level The vessel should be mounted at least 150mm above the highest point of the system and be connected through a non
90. t No 635 The Electricity at Work Regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMPORTANT These appliances are CE certificated for safety and performance It is therefore important that no external control devices e g flue dampers economisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Keston in writing If in doubt please enquire Any direct connection of a control device not approved by Keston could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations SAFE HANDLING OF SUBSTANCES No asbestos mercury or CFCs are included in any part of the boiler or its manufacture Keston Combi Installation and Servicing LOCATION OF BOILER The boiler must be installed on a flat and vertical internal wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority For electrical safety reasons there must be no access available from the back of the boiler The boiler must not be fitted outside Timber Framed Buildings If the boiler is to be fitted in a timber framed building it should be fitted in accorda
91. t all isolation handles are shown in the open postion 24 FILLING FILLING IMPORTANT when filling When filling there may be a slight water leak from the air vent therefore electrical connections should be protected 1 Ensure Filling Loop is connected 2 Ensure dust cap on auto air vent is slackened off refer to Frame 66 3 Check all isolation handles on all water connections are in the open position 4 Open handle on the filling loop then slowly open handle until pressure gauge reads between 1 to 1 5 bar 5 Once pressure gauge dial reads between 1 1 5 bar turn the filling loop isolation valves back to the closed position 6 Disconnect filling loop at the LH side ensuring top hat washer is retained and screw on blanking cap 7 Connect extended blanking cap and top hat washer to filling loop pipe Note Fully open all DHW taps and ensure water is flowing freely Once satisfied close all taps Handle Shown in closed position _ Handle Shown in closed position Safety Drain Valve Keston Combi Installation and Servicing INSTALLATION 23 ELECTRICAL CONNECTIONS WARNING This appliance MUST be earthed A mains supply of 230Vac 50 Hz is required The fuse rating should be 3A All external controls and wiring must be suitable for mains voltage Wiring external to the boiler MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any
92. tallation including the meter should be inspected and tested for tightness and purged in accordance with the recommendations of BS 6891 In IE refer to IS 813 2002 2 Purge air from the gas installation by the approved methods only be in place to ensure that the boiler case sealing is maintained WARNING Whilst effecting the required gas tightness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO NOT SMOKE GENERAL Please Note The combustion for this appliance has been checked adjusted and preset at the factory for operation on the gas type defined on the appliance data plate No measurement of the combustion is necessary DO NOT adjust the air gas ratio valve Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals as described in the Flue Installation section Proceed to put the boiler into operation as follows CHECK THE OPERATIONAL WORKING GAS INLET PRESSURE Set up the boiler to operate at maximum rate by opening hot tap to maximum flow Gas Supply With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point complies with the requirements refer to Gas Supply on page 8 Ensure that this inlet pressure can be obtained with all other gas appliances in the property
93. tat switched on NO Switch the Timer and Room Thermostat On y YES Are the Radiator Valves Open NO Open the Radiator Valves YES Is there 230Vac at A y YES y NO Replace the There is no Voltage from the Diverter Valve Timer Room Stat This is not boiler fault Ensure Voltage is supplied to boiler by rectifying external wiring O Z A LL H lt LL O Z A LL J lt LL O Z A LL J lt LL O a LL J lt LL O a LL H lt LL 62 Keston Combi Installation and Servicing FAULT FINDING 87 NO HW BUT CH ON Is the red neon Is hot and cold illuminated on the turbine pipework crossed sensor Does the display show hot water temperature XX C high efficiency YES Are the flow rates correct as per Frame 2 Adjust flow rates to achieve 35 Rad m temp rise and check filter fitted in YES turbine is not blocked with debris Is the wiring between the PCB and the diverter Reconnect wiring or valve motor connected i replace wiring harness if YES no continuity Is the wiring connected between PCB and DHW sensor Check diverter head fully engaged and clip Re engage diverter secured onto waterset head and secure clip to YES wateset Remove the turbine and check for debris in the NO turbine amp filter Replace Is diverter stuck in the CH position V Replace PCB turbine if necessary Is DHW OK YE Check and replace diverter valve moto
94. test point is provided then a flue integrity check with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the Prior to CO level and combustion ratio check see opposite page before proceeding to the check CO level and combustion ratio at maximum rate stage below Set Boiler to Maximum Gas Rate In accordance with boiler instructions set boiler to operate at maximum rate full load condition Allow sufficient time for combustion to stabilise Note Do not insert analyser probe during this period to avoid possible flooding of sensor Verify Flue Integrity Analyser readings indicate that combustion products and inlet air O2 more than or must be mixing Further investigation of the flue is therefore required equal to 20 6 OR CO2 less than or equal to Check that flue components are assembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed Check CO level and Combustion Ratio at Maximum Gas Rate equal to 20 6 OR CO2 With boiler still set at maximum gas rate ess than or equal tg insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disco
95. th the manufacturer s instructions Self certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist Before installing this boiler read the Code of Practice sheet at the rear of this book BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Make and model Burner operating pressure Appliance serial no on data badge Central heating flow temp measure and record SEDBUK No Central heating return temp measure and record Controls For combination boilers only Scale reducer Hot water mode Heat input Max operating burner pressure Auto bypass Max operating water pressure measure amp record Boiler interlock Cold water inlet temp measure amp record Hot water outlet temp measure amp record Flushing to BS 7593 Water flow rate at max setting measure amp record Inhibitor For condensing boilers only Central heating mode Condensate drain Heat input For all boilers complete sign amp hand over to customer For assistance see Technical Helpline on the back page NOTE TO THE INSTALLER COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE COLLECTIVE MARK INSTRUCTIONS WITH APPLIANCE THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Keston Combi Installation and Servicing 5 GENERAL INTRODUCTION The Keston Co
96. the sealing washer provided Reassemble in the reverse order 7 Refill the boiler Refer to Frame 22 Check the operation of the boiler Refer to Frame 36 54 Keston Combi Installation and Servicing SERVICING 72 HEAT ENGINE RENEWAL Refer also to Frame 6 Boiler Exploded View IMPORTANT Before starting the removal procedure protect the gas and electrical controls with a waterproof sheet or plastic bag 1 Refer to Frame 45 2 Drain the boiler Refer to Frame 60 3 Remove the fan venturi assembly and place on one side Refer to frame 46 4 Remove the burner and place on one side Refer to Frame 48 5 Remove the ignition and detection electrodes and diverter actuator head Refer to Frames 51 52 and 55 6 Remove the spark generator Refer to Frame 53 7 Disconnect flue thermostat 8 Remove the gas valve Refer to Frame 54 9 Remove the expansion vessel Refer to Frame 73 10 Remove the no flow thermistor Refer to Frame 71 11 Remove the 2 M5 screws retaining the gas valve mounting bracket and transfer bracket to the new heat exchanger Keston Combi Installation and Servicing 12 13 14 15 16 17 18 19 20 Undo the inlet pipe union nut and remove the retaining spring clip and remove pipe Undo the flow pipe union nut and remove pipe Remove the condensate rubber pipe Refer to Frame 56 no 2 Remove the two heat exchanger fixing screws Remove the
97. the sequence described 14 WALL MOUNTING TEMPLATE The wall mounting template is located on the internal protective packaging Note The template shows the positions of the fixing holes and the position of the air and flue connections Care MUST be taken to ensure the correct holes are drilled Tape template into the selected position Ensure squareness by hanging a plumbline as shown Mark onto the wall the following a The wall mounting plate screw positions choose one from each group b The position of the air and flue when exiting straight out of the wall where the boiler is mounted Note Mark the centre of the hole as well as the circumference 3 Remove the template from the wall 15 PREPARING THE WALL IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue and air holes preferably with 60mm core bore tool ensuring the holes are square to the wall Drill 2 holes with a 7 5mm 8mm masonry drill and insert the plastic plugs provided for the wall mounting plate Locate 2 No 14 x 50mm screws in the wall mounting plate one at each side in any of the 3 holes provided at each side and screw home 18 Rear flue only 60mm diameter holes Section through wall Note Check all of the hole positions before drilling 3G10030 Keston Combi Installation
98. tomer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Allinstallations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a enchmari Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 03 Signature SERVICE 04 Engineer name Company name Engineer name Company name Telephone No Gas safe r
99. trols Operate each control separately and check that the main burner responds Note The temperature displayed XX C is that measured at that moment not the set temperature 8 Finally set the controls to the User s requirements Notes 1 Ifthe pump has not operated in the last 24 hours it will run briefly to prevent seizure 2 Ifthe diverter valve has not operated in the last 24 hours it will be operated briefly to prevent seizure These two operations will not occur at the same time WATER TEMPERATURES Temperatures can be selected using the CH and DHW thermostats Knob Setting CH Flow Temp DHW Outlet Temp C F C F wua eaa sua aw 35 INSTALLATION INSTALLATION INSTALLATION 37 HANDING OVER After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 1 36 Make the householder aware that the user instructions are located in the pocket in the drop down door and explain his her responsibilities under the relevant national regulations Explain and demonstrate the lighting and shutting down procedures The operation of the boiler and the use and adjustment of all system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption Advise the User of the precautions necessary t
100. uilding Regulations Where this involves notifiable work be a member of a Competent Persons Scheme or confirm that the customer has notified Local Authority Building Control LABC prior to work commencing Complete all relevant sections of the Benchmark Checklist Service Record when carrying out commissioning or servicing of a product or system Ensure that the product or system Is left in a safe condition and whenever possible in good working order Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work Refer to the manufacturer s helpline where assistance Is needed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Hand over the manufacturer s instructions including the Benchmark Checklist to the customer on completion of an installation Obtain the customer s signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer s instructions Advise the customer that regular product servicing is needed in line with manufacturers recommendations to ensure that safety and efficiency is maintained Respond promptly to calls from a custome
101. ve air intake blanking plate by unscrewing 4 x M5 screws and put to one side leaving sponge gasket in place Fix air spigot to boiler using the 4 M5 screws see diag below Ensure sponge gasket is in place and not damaged Insert the flue adaptor into the flue manifold on the top of the boiler and secure using the clamp provided in the packaging box see diagram below Measure cut and check the air and flue pipes to pass to the exit from the wall s or ceiling Always thoroughly deburr all pipes and most important remove shavings from within the pipe Assemble using solvent weld cement the pipework from the boiler connections to the exit from the first wall ceiling remount the boiler if removed When pushing pipe through walls ensure grit and dust is not allowed to enter the pipe Ensure pipes are fully engaged into sockets and solvent welded with no leaks Using the same methods drill any further holes always covering existing pipework cut and assemble the pipework From outside complete the two terminations See Frame 8 Flue System and make good all holes Wall sealing collars are available to make good hole areas on the wall face part number C 08 0 00 07 0 Support any pipes whose route could be displaced either of its own accord or by accident Any horizontal run over 1m or vertical runs of any length must always be supported Brackets should be placed at intervals of approximately 1m Brackets shou

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